This book is to be distributed freely and may be copied or printed as needed. Copyright © 2005 Masterwork Solutions, Inc. 13875 Creekview Dr SW Port Orchard, WA 98367 http://www.masterworksolutions.com All Rights Reserved The information contained in this document is subject to change without notice and should not be considered commitments by Masterwork Solutions, Inc. No material may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Masterwork Solutions, Inc. The documents discussed in this document are furnished under license and may be used or copied only in accordance with the terms of this license. All warranties given by Masterwork Solutions, Inc. are set forth in this document and may not be ammended or modified. As a condition to your use of this product, the user agrees to accept the limited warranty, disclaimer, and other terms and conditions set forth. The Masterwork Solutions, Inc. logo is the trademark of Masterwork Solutions, Inc. Other Product and Company names mentioned herein are the trademarks of their respective owners. Mastercam is a registered trademark of CNC. Windows 95,98,2000 and XP are registered trademarks of Microsoft Corporation. Companies, names, and data used in examples herein are fictitious unless otherwise noted. Complying with all applicable copyright laws is the responsibility of the user. All documents are printed in the United States of America.
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Mastercam X Gears Tutorial
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Contents ■ Shortcut Keys........................................................................................................................................iv ■ Chapter 1: Rotating Gears.....................................................................................................................1 Section 1: Setup.....................................................................................................................................................................2 Section 2: Rectangular Geometry....................................................................................................................................2 Section 3: Post Circles..........................................................................................................................................................3 Section 4: Handle...................................................................................................................................................................4 Section 5: Shaft Circles........................................................................................................................................................5 Section 6: Gears......................................................................................................................................................................5 Section 7: Translate Gears..................................................................................................................................................7 Section 8: Stock Setup.......................................................................................................................................................12 Section 9: First Pocket Toolpath....................................................................................................................................12 Section 10: Second Pocket Toolpath...........................................................................................................................15 Section 11: Verify................................................................................................................................................................18 Section 12: Post Processing.............................................................................................................................................19 ■ Chapter 2: Ring Gear............................................................................................................................21 Section 1: Setup...................................................................................................................................................................22 Section 2: Circles.................................................................................................................................................................22 Section 3: First Gear Ring.................................................................................................................................................24 Section 4: Second Gear Ring...........................................................................................................................................30 Section 5: Angled Gear Surface.....................................................................................................................................36 Section 6: Tapered Gear Surface...................................................................................................................................38 Section 7: Gear Cap Surface............................................................................................................................................40 Section 8: Flat Boundary Surfaces.................................................................................................................................42 Section 9: Ruled Wall Surfaces.......................................................................................................................................43 Section 10: Stock Setup....................................................................................................................................................45 Section 11: Axle Hole Pocket Toolpath (1/5).............................................................................................................46 Section 12: Inside Ring Pocket Toolpath (2/5)..........................................................................................................49 Section 13: Gear Surface Rough Toolpath (3/5).......................................................................................................51 Section 14: Gear Surface Finish Toolpath (4/5)........................................................................................................53 Section 15: Outer Contour Toolpath (5/5).................................................................................................................56 Section 16: Verify................................................................................................................................................................58 Section 17: Post Processing.............................................................................................................................................59 ■ Chapter 3: Spider and Pinion Gears...................................................................................................63 Section 1: Setup...................................................................................................................................................................64 Section 2: Stock Setup.......................................................................................................................................................64 Section 3: Pinion Gear Geometry..................................................................................................................................65 Section 4: Pinion Gear.......................................................................................................................................................66 Section 5: Pinion Gear Surfaces.....................................................................................................................................69 This book is to be distributed freely and may be copied or printed as needed. Masterwork Solutions
i
Table Of Contents
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Section 6: Spider Gear Geometry..................................................................................................................................73 Section 7: Spider Gears.....................................................................................................................................................75 Section 8: Spider Gear Surfaces.....................................................................................................................................86 Section 9: Pinion Gear Toolpaths..................................................................................................................................89 Section 10: Spider Gear Toolpaths...............................................................................................................................97 Section 11: Toolpath Cleanup......................................................................................................................................104 Section 12: 1/8" Toolpath Array..................................................................................................................................105 Section 13: 1/16" Toolpath Array................................................................................................................................107 Section 14: Verify..............................................................................................................................................................109 Section 15: Post Processing..........................................................................................................................................110 ■ Chapter 4: Axle Housing....................................................................................................................113 Section 1: Setup................................................................................................................................................................114 Section 2: Geometry........................................................................................................................................................114 Section 3: Rough Toolpath...........................................................................................................................................115 Section 4: Finish Toolpath.............................................................................................................................................116 Section 5: Drill Toolpath.................................................................................................................................................118 Section 6: Groove Toolpath..........................................................................................................................................120 Section 7: Cutoff Toolpath............................................................................................................................................122 Section 8: Verify................................................................................................................................................................123 Section 9: Post Processing.............................................................................................................................................125 Section 10: Optional Drive Shaft Housing...............................................................................................................126 ■ Chapter 5: Spider Gear Carrier..........................................................................................................127 Section 1: Setup................................................................................................................................................................128 Section 2: Preparation....................................................................................................................................................128 Section 3: Geometry........................................................................................................................................................128 Section 4: Fillets................................................................................................................................................................134 Section 5: Stock Setup....................................................................................................................................................135 Section 6: Contour Toolpath........................................................................................................................................136 Section 7: Verify................................................................................................................................................................139 Section 8: Post Processing.............................................................................................................................................139 ■ Chapter 6: Crank and Wheel Hubs....................................................................................................141 Section 1: Setup................................................................................................................................................................142 Section 2: Stock Setup....................................................................................................................................................142 Section 3: Wheel Hub Geometry.................................................................................................................................143 Section 4: Copy Wheel Hub..........................................................................................................................................144 Section 5: Crank................................................................................................................................................................145 Section 6: Drill Points......................................................................................................................................................148 Section 7: Pocket Toolpath...........................................................................................................................................149 Section 8: Drill Toolpath.................................................................................................................................................152 Section 9: Contour Toolpath........................................................................................................................................154 Section 10: Verify..............................................................................................................................................................156 Section 11: Post Processing..........................................................................................................................................157 ■ Chapter 7: Differential Assembly.....................................................................................................159 This book is to be distributed freely and may be copied or printed as needed.
ii
Masterwork Solutions
Mastercam X Gears Tutorial
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Section 1: Materials: Spacers, Rods and Axles........................................................................................................160 Section 2: Materials: Frame...........................................................................................................................................160 Section 3: Assembly.........................................................................................................................................................161 ■ Appendix A.........................................................................................................................................167 Section 1: Elements of a Gear Tooth.........................................................................................................................168 Section 2: Gear Parameters...........................................................................................................................................169 Section 3: Bevel Gears.....................................................................................................................................................170 Section 4: 2D Tooth to 3D Tooth................................................................................................................................172
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iii
Shortcut Keys
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Shortcut Keys About Mastercam X
ALT + V
Analyze
F4
Auto Save Parameters
ALT + A
Copy
CTRL + C
Cut
CTRL + X
Delete
F5
Drafting Settings
ALT + D
Exit
ALT + F4
Fit Screen
ALT + F1
Grid Settings
ALT + G
Gview Top
ALT + 1
Gview Front
ALT + 2
Gview Back
ALT + 3
Gview Bottom
ALT + 4
Gview Right
ALT + 5
Gview Left
ALT + 6
Gview Isometric
ALT + 7
Help
ALT + H
Hide Entities
ALT + E
Level Manager
ALT + Z
Mastercam X Configuration
ALT + F8
Previous Gview
ALT + P
Paste
CTRL + V
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iv
Masterwork Solutions
Mastercam X Gears Tutorial
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Redo
CTRL + Y
Regenerated On Screen Entities
SHIFT + CTRL + R
Repaint Screen Run User Application (C-Hook) Select All
F3 ALT + C CTRL + A
Set Attributes From Selected Entity Set Motion Controller Rotation Center Point Toggle Axis Display
ALT + X ALT + F12 F9
Toggle WCS Axis Display
ALT + F9
Toggle Toolpath Display
ALT + T
Toggle Shading
ALT + S
Toggle Toolpaths / Solids Tab
ALT + O
Undo
ALT + U
Undo
CTRL + Z
Undo
CTRL + U
Unzoom by 0.8 Zoom Target Zoom Window
F2 CTRL + F1 F1
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v
Shortcut Keys
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vi
Masterwork Solutions
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Chapter
1 Geometry
Rotating Gears
➤ About this project:
Abstract Introduces basic concepts of creating gears.
Toolpath
Description Create three gears and posts that, when assembled, will interlock and rotate.
Materials 4.5"x4.4"x0.75" Protofoam Block.
Machines 1/8" Flat Endmill.
Verified
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Chapter 1: Rotating Gears
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Section 1: Setup Start Mastercam X. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X does not do this automatically. ■ select Machine Type -> Mill -> Your Machine If you have not created a Mastercam X Machine Definition for your machine, or if no machine is available, choose the default machine: ■ select Machine Type -> Mill -> 3 - Axis VMC.MMD Mastercam X creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Rectangular Geometry Create three rectangles that will serve as base geometry for the solids. ■ select Create -> Create Rectangle... Mastercam X prompts for a location to create the rectangle. Set the width and height: ■ ■ ■ ■
press W type 4.5 press ENTER press H type 4.5 press ENTER
Enter the placement location: ■ press SPACE ■ type X0.0 Y0.0 press ENTER Mastercam X creates the first rectangle. ■ select Apply Set the width/height for the second: ■ ■ ■ ■
press W type 4.25 press ENTER press H type 4.25 press ENTER
Enter the placement location: ■ press SPACE ■ type X0.125 X0.125press ENTER ■ select Apply Finally, create a third rectangle: ■ ■ ■ ■ ■ ■
press SPACE type X0.375 Y3.125press ENTER press SPACE type X4.125 Y4.125 press ENTER select OK press ALT-F1
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Mastercam X creates three rectangles. Your drawing should look like Figure 1.2.1.
Figure 1.2.1: Three rectangles.
Section 3: Post Circles Now, create circles to be used as posts: ■ select Create -> Arc -> Create Circle Center Point... Set the diameter: ■ ■ ■ ■ ■
press D type 0.38 press ENTER press SPACE type X1.0 Y3.625 press ENTER select Apply
Mastercam X creates the first post. Create the second two: ■ select Diameter ■ type 0.28 press ENTER Mastercam X locks the diameter at 0.28. Any future circles will be created with this diameter, instead of requesting a new diameter for each one. ■ ■ ■ ■ ■
press SPACE type X2.53 Y3.625 press ENTER press SPACE type X3.58 Y3.625 press ENTER select OK
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3
Chapter 1: Rotating Gears
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Mastercam X creates the post circles. Your drawing should look like Figure 1.3.1.
Figure 1.3.1: Post circles.
Section 4: Handle Create a circle that will be used to make a handle for the large gear: ■ select Create -> Arc -> Create Circle Center Point... Set the diameter: ■ press D ■ type 0.2 press ENTER Enter the center point: ■ type X1.5 Y2.125 press ENTER ■ select OK Mastercam X creates the handle circle. Your drawing should look like Figure 1.4.1.
Figure 1.4.1: Circle for handle. Save your drawing: ■ select File -> Save
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Mastercam X displays a Save dialog. In the File name field:
■ type ROTATE plus your initials. Example: ROTATENWT ■ select Save Mastercam X saves your file.
Section 5: Shaft Circles Create three circles that will be used as shafts for the gears: ■ select Create -> Arc -> Create Circle Center Point... Set the diameter: ■ press D ■ type 0.4 press ENTER Enter the center point: ■ press SPACE ■ type X1.5 Y1.5 press ENTER ■ select Apply Set the diameter for the next two circles: ■ select Diameter ■ type 0.3 press ENTER Enter the center points: ■ ■ ■ ■ ■
press SPACE type X3.5 Y1.0 press ENTER press SPACE type X3.5 Y2.3 press ENTER select OK
Mastercam X creates the circles. Your drawing should look like Figure 1.5.1.
Figure 1.5.1: Circles for shaft.
Section 6: Gears Next, create the gears:
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5
Chapter 1: Rotating Gears
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■ select Settings -> Run User Application... Mastercam X displays the Open dialog. ■ select the Gear.dll file ■ select Open
Mastercam X displays the Gear dialog. Set your parameters as shown in Figure 1.6.1.
Figure 1.6.1: Parameters for the first gear. ■ select OK Mastercam X creates the first gear. Create the second: ■ select Settings -> Run User Application... Mastercam X displays the Open dialog. ■ select the Gear.dll file ■ select Open
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6
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Mastercam X displays the Gear dialog. Set your parameters as shown in Figure 1.6.2.
Figure 1.6.2: Parameters for the second gear. ■ select OK Mastercam X creates the second gear. ■ press ALT-F1 Your drawing should look like Figure 1.6.3.
Figure 1.6.3: Two gears.
Section 7: Translate Gears Now that the gears have been created, translate them to their shafts: ■ select Xform -> Xform Translate... Mastercam X prompts for entities to translate. Change your selection mode to chain:
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7
Chapter 1: Rotating Gears
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■ select Chain
in the toolbar
Mastercam X will now select a chain of geometry. ■ select anywhere on the larger gear ■ select End Selection Mastercam X displays the Translate dialog. ■ select Move Translate between two points: ■ select Select FROM point Mastercam X prompts for a point:
■ select Origin
Select the second point:
■ select Arc Center
Mastercam X prompts for an arc: ■ select the largest shaft circle as shown in Figure 1.7.1
Figure 1.7.1: Select this circle. Mastercam X displays a preview of the translated gear. ■ select Apply
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Mastercam X translates the gear. Your drawing should look like Figure 1.7.2.
Figure 1.7.2: Large gear in position. Mastercam X is still prompting for geometry to select. ■ select anywhere on the smaller gear ■ select End Selection Mastercam X displays the Translate dialog. ■ select Copy Translate between two points: ■ select Select FROM point Mastercam X prompts for a point:
■ select Origin
Select the second point:
■ select Arc Center
Mastercam X prompts for an arc:
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9
Chapter 1: Rotating Gears
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■ select the top shaft circle as shown in Figure 1.7.3
Figure 1.7.3: Select this circle. Mastercam X displays a preview of the translated gear. ■ select Apply Mastercam X translates the second gear, creating a copy and preserving the original. Your drawing should look like Figure 1.7.4.
Figure 1.7.4: Second translated gear. Finally, translate the third gear: ■ select anywhere on the smaller gear ■ select End Selection Mastercam X displays the Translate dialog. ■ select Move Translate between two points: ■ select Select FROM point Mastercam X prompts for a point:
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10
This book is to be distributed freely and may be copied or printed as needed. ■ select Origin
Select the second point:
■ select Arc Center
Mastercam X prompts for an arc: ■ select the bottom shaft circle as shown in Figure 1.7.5
Figure 1.7.5: Select this circle. Mastercam X displays a preview of the translated gear. ■ select OK Mastercam X translates the third gear. Your drawing should look like Figure 1.7.6.
Figure 1.7.6: Third translated gear. Save your drawing:
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11
Chapter 1: Rotating Gears
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■ select File -> Save
Section 8: Stock Setup Before creating the toolpath, tell Mastercam X what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
■ select Stock Setup
Mastercam X displays the Stock Setup dialog. Set your parameters as shown in Figure 1.8.1:
Figure 1.8.1: Stock Setup dialog. ■ select OK
Section 9: First Pocket Toolpath Create the first pocket toolpath: ■ select Toolpaths -> Pocket Toolpath... Mastercam X displays the Chaining window and promtps for geometry to prompt.
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12
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■ select the rectangle and arcs shown in
Figure 1.9.1: Selection for first pocket. ■ select OK Mastercam X displays the Pocket (Standard) dialog. Choose a tool: ■ select Select library tool... Mastercam X displays the Tool Selection dialog. ■ select #232 Endmill1 Flat 0.125" as shown in Figure 1.9.2
Figure 1.9.2: #232 1/8" endmill. ■ select OK Mastercam X redisplays the Pocket (Standard) window. There are three tabs of parameters, do not press OK until all are set.
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13
Chapter 1: Rotating Gears
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Set your Toolpath Parameters as shown in Figure 1.9.3.
Figure 1.9.3: Toolpath Parameters. Set your Pocketing Parameters as shown in Figure 1.9.4.
Figure 1.9.4: Pocketing Parameters. Set the depth cuts parameters: ■ select Depth cuts... Mastercam X displays the Depth cuts window. Set your parameters as shown in Figure 1.9.5.
Figure 1.9.5: Depth cuts parameters.
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14
This book is to be distributed freely and may be copied or printed as needed. ■ select OK Set your Roughing/Finishing Parameters as shown in Figure 1.9.6.
Figure 1.9.6: Roughing/Finishing Parameters. ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 1.9.7.
Figure 1.9.7: First pocket toolpath.
Section 10: Second Pocket Toolpath Pocket the area around the gears: Turn off display of the first pocket toolpath: ■ select Select All Operations ■ select Toggle Toolpath Display Mastercam X turns off displays of the first toolpath. ■ select Toolpaths -> Pocket Toolpath...
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15
Chapter 1: Rotating Gears
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Mastercam X prompts for geometry to pocket.
■ select the rectangles, gears, and arcs in Figure 1.10.1
Figure 1.10.1: Selection for second pocket toolpath. ■ select OK Mastercam X displays the Pocket (Island facing) window. There are three tabs of parameters, do not press OK until all are set. Use the same tool from the first pocket toolpath: Set your Toolpath Parameters as shown in Figure 1.10.2.
Figure 1.10.2: Toolpath Parameters.
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This book is to be distributed freely and may be copied or printed as needed.
Set your Pocketing Parameters as shown in Figure 1.10.3.
Figure 1.10.3: Pocketing Parameters. Set your Roughing/Finishing Parameters as shown in Figure 1.10.4.
Figure 1.10.4: Roughing/Finishing Parameters. ■ select OK
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17
Chapter 1: Rotating Gears
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Mastercam X creates the toolpath. Your drawing should look like Figure 1.10.5.
Figure 1.10.5: Second pocket toolpath. Turn on both toolpaths: ■ select Select All Operations ■ select Toggle Toolpath Display Mastercam X your drawing should look like Figure 1.10.6.
Figure 1.10.6: Both pocket toolpaths. Save your drawing: ■ select File -> Save
Section 11: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7
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This book is to be distributed freely and may be copied or printed as needed.
■ press ALT-F1
Mastercam X displays the Verify Controller, changes your view to isometric and fits your part to screen. ■ select Simulate Tool ■ select Machine Mastercam X machines your part. You can control the speed and quality by adjusting the options in the Verify Controller. When your part is machined, it should look like Figure 1.11.1.
Figure 1.11.1: Verified gear assembly. If it does: ■ select OK Mastercam X exits verify mode.
Section 12: Post Processing Now that you have verified your part, it is time to generate NC code so that you can machine a real part. In the Toolpaths tab on the left of the Mastercam X window: ■ select Select All Operations ■ select Post Selected Operations Mastercam X displays the Post Processing dialog. ■ select Select Post Mastercam X displays the Open dialog. ■ select the post that matches your machine ■ select Open
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19
Chapter 1: Rotating Gears
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Match the other settings with those shown in Figure 1.12.1.
Figure 1.12.1: Post Processing. ■ select OK Mastercam X displays a Save dialog for you to save your NC file. In the File name field: ■ type ROTATE plus your initials. Example: ROTATENWT ■ select Save Mastercam X saves your NC file. You can use this to machine your part, if you want. Finally, save your file: ■ select File -> Save Since you saved your file before, Mastercam X silently saves the changes you have made since then, without prompting again for a file name.
Congratulations! You have completed the Rotated Gear Exercise!
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20
This book is to be distributed freely and may be copied or printed as needed.
Chapter
2 Geometry
Ring Gear
➤ About this project:
Toolpath
Abstract Create a complex gear using surfaces.
Description The ring gear uses three surfaces to give it angle and taper. The gears are made by transforming and rotating a single tooth.
Materials 3"x3"x0.75" Protofoam Block.
Machines 1/4" Flat Endmill, 1/16" Ball Endmill
Verified
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Chapter 2: Ring Gear
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Section 1: Setup Start Mastercam X. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X does not do this automatically. ■ select Machine Type -> Mill -> Your Machine If you have not created a Mastercam X Machine Definition for your machine, or if no machine is available, choose the default machine: ■ select Machine Type -> Mill -> 3 - Axis VMC.MMD Mastercam X creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Circles The first step in the Ring Gear exercise is to create supporting geometry. Create a series of circles: Change the 2D/3D mode to 2D: ■ select 3D at the bottom of the Mastercam X window 3D changes to 2D. In the Z: field at the bottom of the Mastercam X window: ■ type -0.25 press ENTER Create the circles: ■ select Create -> Arc -> Create Circle Center Point... Circles 1-2: ■ press R ■ type .75 press ENTER ■ select Origin
in the toolbar
■ select Apply ■ ■ press R ■ type 1.0 press ENTER ■ select Origin
in the toolbar
■ select Apply Mastercam X creates the first two circles. In the Z: field at the bottom of the Mastercam X window ■ type -0.325 press ENTER Circles 3-5: ■ select the Radius field (Do not press R) ■ type 0.75 press ENTER
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This book is to be distributed freely and may be copied or printed as needed. ■ select Origin
in the toolbar
■ select Apply ■ ■ press R ■ type 1.25 press ENTER ■ select Origin
in the toolbar
■ select Apply ■ ■ press R ■ type 0.1375 press ENTER ■ select Origin
in the toolbar
■ select Apply Mastercam X creates the circles. Your drawing should look like Figure 2.2.1.
Figure 2.2.1: Five circles. In the Z: field at the bottom of the Mastercam X window: ■ type -0.45 press ENTER Circles 6-8: ■ select the Radius field (Do not press R) ■ type 0.1375 press ENTER ■ select Origin
in the toolbar
■ select Apply ■ ■ press R ■ type 1.25 press ENTER
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23
Chapter 2: Ring Gear
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■ select Origin
in the toolbar
■ select Apply ■ ■ press R ■ type 1.5 press ENTER ■ select Origin
in the toolbar
■ select OK Mastercam X creates the remaining circles. Your drawing should look like Figure 2.2.2.
Figure 2.2.2: All eight circles. Now is a good time to save your drawing: Mastercam X displays a Save dialog. In the File name field: ■ type RING plus your initials. Example: RINGNWT ■ select Save Mastercam X saves your file.
Section 3: First Gear Ring Next, create the first gear ring. This will be used as one contour for the gear surface. Switch to Isometric view: ■ press ALT-7 ■ press ALT-F1 Change your 2D/3D back to 3D: ■ select 2D at the bottom of the Mastercam X window 2D changes to 3D.
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24
This book is to be distributed freely and may be copied or printed as needed.
Your drawing should look like Figure 2.3.1.
Figure 2.3.1: Circles in Isometric view. Change the construction color to brown: ■ select the green color swatch at the bottom of the Mastercam X window Mastercam X diplays the Color dialog. ■ select the #6 brown color ■ select OK Mastercam X will create the gear in brown. Create the gear tooth: ■ select Settings -> Run User Application ■ - OR ■ press ALT-C Mastercam X displays the Open dialog. ■ select Gear.dll ■ select Open Mastercam X displays the Gear dialog. Match your settings with those shown in Figure 2.3.2. Make sure to press ENTER after setting each parameter, as Mastercam X will calculate the other parameters to match your input.
Figure 2.3.2: Gear parameters for the first tooth.
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25
Chapter 2: Ring Gear
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■ select OK Mastercam X creates the gear. Your drawing should look like Figure 2.3.3.
Figure 2.3.3: First tooth. Next, translate the gear to the proper position: ■ select Xform -> Xform Translate... Mastercam X prompts for geometry. ■ select All... in the toolbar Mastercam X displays the Select All Window. ■ select Color Mastercam X displays the used colors in a list below. ■ select the brown color by double-clicking it Mastercam X closes the Select All window and select the gear tooth: ■ select End Selection Mastercam X displays the Translate dialog. ■ select Move Mastercam X in the ΔZ field: ■ type -0.325 press ENTER ■ select OK Mastercam X translates the tooth to be on the same level as the circle. Your drawing should look like Figure 2.3.4.
Figure 2.3.4: First tooth translated to the proper Z depth.
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26
This book is to be distributed freely and may be copied or printed as needed.
Next, create a point at the intersection of the gear tooth and the circle to use as a rotation point for the tooth. First, zoom in: ■ press F1 Mastercam X enters zoom mode. Drag a zoom window as shown in Figure 2.3.5.
Figure 2.3.5: Zoom in close to the first tooth. Create the point: ■ select Create -> Point -> Create Point Position... Mastercam X prompts for a location to create the point. You will select the right interstection of the tooth and the circle. The autocursor will snap to the intersection when you move the mouse close to it. When it does, the cursor will display a small X next to it. When this X is shown, clicking the mouse will select the interesection. ■ select the intersection of the first tooth and the circle as shown in Figure 2.3.6
Figure 2.3.6: Select the intersection of the tooth and the circle. Mastercam X creates the point. Since it is dark and very small, it might be difficult to see. Change your Cplane to Right Side: ■ select Planes -> Right Side at the bottom of the Mastercam X window Next, rotate the tooth around this point: ■ select Xform -> Xform Rotate... Mastercam X prompts for geometry. You will select the tooth by selecting all geometry with the #6 brown color. ■ ■ ■ ■
select All... select Color select the brown color by double-clicking on it select End Selection
Mastercam X displays the Rotate dialog. ■ select Define Center Mastercam X prompts for a center point. Use point selection mode to select the point:
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27
Chapter 2: Ring Gear
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■ select Point
Mastercam X will only select points. ■ select the intersection point you just created Due to the size of the point relative to the surrounding geometry, you may not be able to notice that the point is highlighted when you mouse over it. However, if you click directly on the intersection of the tooth and the circle, Mastercam X will select the point. ■ select Move In the angle field: ■ type 73.3 press ENTER Perform the rotation: ■ select OK ■ press ALT-F1 Mastercam X rotates the tooth. Your drawing should look like Figure 2.3.7.
Figure 2.3.7: First tooth rotated. Delete the point: ■ ■ ■ ■
select All... select Entities (NOT All Entities) select Points by double clicking on it press DELETE
Mastercam X removes the point. Change your Cplane to Top: ■ select Planes -> Top Now, create copies of this tooth to make the gear: ■ select Xform -> Xform Rotate... Mastercam X prompts for geometry to rotate: ■ ■ ■ ■
select All... select Color select the brown color by double-clicking it select End Selection
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X displays the Rotate dialog. In the # field: ■ type 39 press ENTER In the angle field: ■ type 360/40 press ENTER Change the mode to copy: ■ select Copy
Mastercam X does the math for you and displays a preview of the rotation. ■ select OK Mastercam X rotates copies of the tooth around the origin to form the gear. Your drawing should look like Figure 2.3.8.
Figure 2.3.8: First gear. Notice that there is a small gap between each of the teeth on the gear. This will need to be filled with a line. You will create a line connecting two teeth and rotate it around 39 times to fill the other gaps. First, zoom in on the gap: ■ press F1 Drag a selection window as shown in Figure 2.3.9.
Figure 2.3.9: Zoom in on the gap. Mastercam X zooms in. There should be a purple tooth on the left, and a red tooth on the right. ■ select Create -> Line -> Create Line Endpoint... Mastercam X prompts for endpoints to create a line.
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Chapter 2: Ring Gear
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■ select the right endpoint on the purple tooth ■ select the left endpoint on the red tooth ■ select OK
Mastercam X creates the line joining the teeth. Rotate this to fill the other 39 gaps: ■ select Xform -> Xform Rotate... Mastercam X prompts for geometry. ■ select the small brown line you just created ■ select End Selection ■ press ALT-F1 Mastercam X displays the Rotate dialog. The center of rotation defaults to the Origin. In the # field: ■ type 39 press ENTER In the angle field: ■ type 360/40 press ENTER Mastercam X does the math for you and displays a preview of the rotated filler line. The 40 teeth turn brown, and the lines are purple and red. ■ select OK ■ select Screen -> Clear Colors Your drawing should look like Figure 2.3.10.
Figure 2.3.10: First gear complete.
Section 4: Second Gear Ring Next, create the second gear ring. This will be used as one contour for the gear surface. Change the construction color to dark green: ■ select the green color swatch at the bottom of the Mastercam X window Mastercam X diplays the Color dialog. ■ select the #2 dark green color ■ select OK Mastercam X will create the gear in dark green. Create the gear tooth: ■ select Settings -> Run User Application
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This book is to be distributed freely and may be copied or printed as needed.
■ - OR ■ press ALT-C
Mastercam X displays the Open dialog. ■ select Gear.dll ■ select Open Mastercam X displays the Gear dialog. Match your settings with those shown in Figure 2.4.1. Make sure to press ENTER after setting each parameter, as Mastercam X will calculate the other parameters to match your input.
Figure 2.4.1: Gear parameters for the second tooth. ■ select OK Mastercam X creates the gear. Your drawing should look like Figure 2.4.2.
Figure 2.4.2: Second tooth. Next, translate the gear to the proper position: ■ select Xform -> Xform Translate... Mastercam X prompts for geometry. ■ select All... in the toolbar Mastercam X displays the Select All Window.
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Chapter 2: Ring Gear
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■ select Color
Mastercam X displays the used colors in a list below. ■ select the dark green color by double-clicking it Mastercam X closes the Select All window and select the gear tooth: ■ select End Selection Mastercam X displays the Translate dialog. ■ select Move In the ΔZ field: ■ type -0.25 press ENTER ■ select OK Mastercam X translates the tooth to be on the same level as the circle. Your drawing should look like Figure 2.4.3.
Figure 2.4.3: Second tooth translated to the proper Z depth. Next, create a point at the intersection of the gear tooth and the circle to use as a rotation point for the tooth. Second, zoom in: ■ press F1 Mastercam X enters zoom mode. Drag a zoom window as shown in Figure 2.4.4.
Figure 2.4.4: Zoom in close to the second tooth. Create the point: ■ select Create -> Point -> Create Point Position...
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X prompts for a location to create the point. You will select the right interstection of the tooth and the circle. The autocursor will snap to the intersection when you move the mouse close to it. When it does, the cursor will display a small X next to it. When this X is shown, clicking the mouse will select the interesection. ■ select the intersection of the second tooth and the circle as shown in Figure 2.4.5
Figure 2.4.5: Select the intersection of the tooth and the circle. Mastercam X creates the point. Since it is very small, it might be difficult to see. Change your Cplane to Right Side: ■ select Planes -> Right Side at the bottom of the Mastercam X window Next, rotate the tooth around this point: ■ select Xform -> Xform Rotate... Mastercam X prompts for geometry. You will select the tooth by selecting all geometry with the #2 dark green color. ■ ■ ■ ■
select All... select Color select the dark green color by double-clicking on it select End Selection
Mastercam X displays the Rotate dialog. ■ select Define Center Mastercam X prompts for a center point. Use point selection mode to select the point:
■ select Point
Mastercam X will only select points. ■ select the intersection point you just created Due to the size of the point relative to the surrounding geometry, you may not be able to notice that the point is highlighted when you mouse over it. However, if you click directly on the intersection of the tooth and the circle, Mastercam X will select the point. ■ select Move In the angle field: ■ type 73.3 press ENTER Perform the rotation:
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Chapter 2: Ring Gear
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■ select OK ■ press ALT-F1 Mastercam X rotates the tooth. Your drawing should look like Figure 2.4.6.
Figure 2.4.6: Second tooth rotated. Delete the point: ■ ■ ■ ■
select All... select Entities (NOT All Entities) select Points by double clicking on it press DELETE
Mastercam X removes the point. Change your Cplane to Top: ■ select Planes -> Top Now, create copies of this tooth to make the gear: ■ select Xform -> Xform Rotate... Mastercam X prompts for geometry to rotate: ■ ■ ■ ■
select All... select Color select the dark green color by double-clicking it select End Selection
Mastercam X displays the Rotate dialog. In the # field: ■ type 39 press ENTER In the angle field: ■ type 360/40 press ENTER Change the mode to copy: ■ select Copy Mastercam X does the math for you and displays a preview of the rotation. ■ select OK
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X rotates copies of the tooth around the origin to form the gear. Your drawing should look like Figure 2.4.7.
Figure 2.4.7: Second gear. Notice that there is a small gap between each of the teeth on the gear. This will need to be filled with a line. You will create a line connecting two teeth and rotate it around 39 times to fill the other gaps. First, zoom in on the gap: ■ press F1 Drag a selection window as shown in Figure 2.4.8.
Figure 2.4.8: Zoom in on the gap. Mastercam X zooms in. There should be a purple tooth on the left, and a red tooth on the right. ■ select Create -> Line -> Create Line Endpoint... Mastercam X prompts for endpoints to create a line. ■ select the right endpoint on the purple tooth ■ select the left endpoint on the red tooth ■ select OK Mastercam X creates the line joining the teeth. Rotate this to fill the other 39 gaps: ■ select Xform -> Xform Rotate... Mastercam X prompts for geometry. ■ select the small dark green line you just created ■ select End Selection ■ press ALT-F1 Mastercam X displays the Rotate dialog. The center of rotation defaults to the Origin.
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Chapter 2: Ring Gear
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In the # field:
■ type 39 press ENTER In the angle field: ■ type 360/40 press ENTER Mastercam X does the math for you and displays a preview of the rotated filler line. The 40 teeth turn dark green, and the lines are purple and red. ■ select OK ■ select Screen -> Clear Colors Your drawing should look like Figure 2.4.9.
Figure 2.4.9: Second gear complete. Save your drawing: ■ select File -> Save
Section 5: Angled Gear Surface Now that the base geometry is complete, we can begin to create surfaces. The first surface we will create is slanted gear, made by connecting the two gears, brown and gray, that you have created. Change the color to red: ■ select the #2 dark green swatch at the bottom of the Mastercam X window Mastercam X displays the Colors dialog. ■ select the #12 red ■ select OK Mastercam X will create future geometry in red. First, however, we have to break the top of one of the teeth on each gear into two pieces, so that the surface can start at the same location on each gear. ■ select Edit -> Trim/Break -> Break Many Pieces Mastercam X prompts for entities to break/extend. First, zoom in on the object to break: ■ press ALT-1 ■ press ALT-F1 ■ press F1
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This book is to be distributed freely and may be copied or printed as needed.
Drag a zoom rectangle around the two teeth as shown in Figure 2.5.1.
Figure 2.5.1: Drag a zoom window here. Break each piece into two pieces: ■ select Number ■ type 2 press ENTER Mastercam X will split each piece of geometry you select into two pieces. ■ select the two lines as shown in Figure 2.5.2
Figure 2.5.2: Select these two lines to break. ■ select OK Now, create the surface: ■ select Create -> Surface -> Create Ruled / Lofted Surfaces... Mastercam X prompts for chains of geometry to create a surface. You will have to select both the green gear and the brown gear in the same location. When you broke the top gear line, two lines were created in it's place. You will need to select the base (lower end) of the top line on each gear. The selection will look much like Figure 2.5.2. Note that the lines on both gears are red, and do not match the color of the other teeth on the gear. ■ select the bottom of the top lines on each arc
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Chapter 2: Ring Gear
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It is important that both arrows start from the same vertical position, and that they both face the same way. If they don't, either reverse the direction or reselect the geometry. ■ select OK Mastercam X displays a preview of the surface. ■ ■ ■ ■
select OK press ALT-7 press ALT-F1 select Shaded
in the toolbar
Your drawing should look like Figure 2.5.3.
Figure 2.5.3: Angled gear surface. If it does not, delete the surface and retry this section. Save your drawing: ■ select File -> Save
Section 6: Tapered Gear Surface The next gear surface will be a taper between the angled gear surface and the second-largest top circle. You will first need to change to Top view and zoom in again. ■ ■ ■ ■
press ALT-1 press ALT-F1 select Wireframe press F1
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This book is to be distributed freely and may be copied or printed as needed.
Drag a zoom window as shown in Figure 2.6.1.
Figure 2.6.1: Drag your zoom rectangle here. ■ select Create -> Surface -> Create Ruled / Lofted Surfaces... Mastercam X prompts for geometry to create a surface: ■ select exactly on the bottom of the red line as shown in Figure 2.6.2 Mastercam X it is very important to select in the correct location.
Figure 2.6.2: Select the bottom of the red line. Switch to Isometric view to select the other geometry: ■ press ALT-7
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Chapter 2: Ring Gear
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■ select select the circle as shown in Figure 2.6.3
Figure 2.6.3: Select this circle. Create the surface: ■ select OK Mastercam X creates a preview of the surface. ■ select OK ■ select Shaded
in the toolbar
Your drawing should look like Figure 2.6.4.
Figure 2.6.4: Completed taper surface. If your surface is twisted, delete it and try this section again. Make sure to select the geometry EXACTLY as instructed. Save your drawing: ■ select File -> Save
Section 7: Gear Cap Surface The next surface will cap the open side of the angled gear surface. First, zoom in close to select the geometry: ■ press F1
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This book is to be distributed freely and may be copied or printed as needed.
Drag a zoom window as shown in Figure 2.7.1.
Figure 2.7.1: Zoom here. Create the surface: ■ select Create -> Surface -> Create Ruled / Lofted Surfaces... ■ select the circle as shown in Figure 2.7.2 Directly above where you select the circle, you will notice a red line on the top of the gear tooth. This red line is actually the two lines you made when you split the tooth top eariler. You will need to select the leftmost edge of the right line, as shown in Figure 2.7.2. ■ select the leftmost edge of the right red line as shown in Figure 2.7.2
Figure 2.7.2: Select the gear. If the arrow does not face the same as the one on the circle: ■ select Reverse Create the surface: ■ select OK ■ select OK ■ press ALT-F1
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Chapter 2: Ring Gear
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The surface should be "straight", as shown in Figure 2.7.3.
Figure 2.7.3: Cap surface complete. If it is twisted, delete it and try this section again, paying special attention to the location and direction of your selection. Save your drawing: ■ select File -> Save
Section 8: Flat Boundary Surfaces You will now create several flat boundary surfaces to flesh out the remainder of the ring gear. ■ select Create -> Surface -> Create Flat Boundary Surface... Mastercam X prompts for geometry. ■ select the two circles as shown in Figure 2.8.1
Figure 2.8.1: Selection for the base flat boundary surface. ■ select OK ■ select Apply Create the inside ring surface:
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This book is to be distributed freely and may be copied or printed as needed.
■ select the two circles as shown in Figure 2.8.2
Figure 2.8.2: Selection for the ring flat boundary surface. ■ select OK ■ select OK Your drawing should look like Figure 2.8.3.
Figure 2.8.3: Completed flat boundary surfaces.
Section 9: Ruled Wall Surfaces The final two surfaces you will create will serve as side walls for the inner ring and the axle hole. Create the wall of the inside ring: ■ select Create -> Surface -> Create Ruled / Lofted Surfaces...
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Chapter 2: Ring Gear
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■ select the two circles as shown in Figure 2.9.1
Figure 2.9.1: Selection for the ring wall ruled surface. ■ select OK ■ select Apply Create the wall of the axle hole: ■ select the two circles as shown in Figure 2.9.2
Figure 2.9.2: Selection for the shaft wall ruled surface. ■ select OK ■ select OK
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X creates the two ruled surfaces. Your drawing should look like Figure 2.9.3.
Figure 2.9.3: Completed ring gear geometry. Save your drawing: ■ select File -> Save
Section 10: Stock Setup Before creating the toolpath, tell Mastercam X what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
■ select Stock Setup
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Chapter 2: Ring Gear
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Mastercam X displays the Stock Setup dialog. Set your parameters as shown in Figure 2.10.1:
Figure 2.10.1: Stock Setup dialog. ■ select OK
Section 11: Axle Hole Pocket Toolpath (1/5) The first toolpath you will create is a pocket that will machine the axle hole. ■ select Toolpaths -> Pocket Toolpath... Mastercam X prompts for geometry to toolpath. ■ select the top axle hole circle as shown in Figure 2.11.1
Figure 2.11.1: Select this top circle. ■ select OK
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X displays the Pocket (Standard) window. Select a tool: ■ select Select library tool... Mastercam X displays the Tool Selection dialog.
■ select #235 Endmill1 Flat 0.2500" as shown in Figure 2.11.2
Figure 2.11.2: #235 1/4" endmill. ■ select OK Set your Toolpath Parameters as shown in Figure 2.11.3.
Figure 2.11.3: Toolpath Parameters.
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Chapter 2: Ring Gear
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Set your Pocketing Parameters as shown in Figure 2.11.4.
Figure 2.11.4: Pocketing Parameters. ■ select Depth cuts... Mastercam X displays the Depth cuts window. Set your parameters as shown in Figure 2.11.5.
Figure 2.11.5: Depth cuts. ■ select OK Set your Roughing/Finishing Parameters as shown in Figure 2.11.6.
Figure 2.11.6: Roughing/Finishing Parameters.
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This book is to be distributed freely and may be copied or printed as needed. ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 2.11.7.
Figure 2.11.7: Axle pocket toolpath. Save your drawing: ■ select File -> Save
Section 12: Inside Ring Pocket Toolpath (2/5) The second toolpath you will create is to pocket the indented inner ring. ■ select Toolpaths -> Pocket Toolpath... Mastercam X prompts for geometry. ■ select the top ring circle as shown in Figure 2.12.1
Figure 2.12.1: Select this circle. ■ select OK Mastercam X displays the Pocket (Standard) window. Use the same tool from the last toolpath:
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Chapter 2: Ring Gear
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Set your Toolpath Parameters as shown in Figure 2.12.2.
Figure 2.12.2: Toolpath Parameters. Set your Pocketing Parameters as shown in Figure 2.12.3.
Figure 2.12.3: Pocketing Parameters. The depth cut settings from the previous toolpath are retained.
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This book is to be distributed freely and may be copied or printed as needed.
Set your Roughing/Finishing Parameters as shown in Figure 2.12.4.
Figure 2.12.4: Roughing/Finishing Parameters. ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 2.12.5.
Figure 2.12.5: Ring pocket toolpath. Save your drawing: ■ select File -> Save
Section 13: Gear Surface Rough Toolpath (3/5) Next, create a rough toolpath to machine the gear surfaces. ■ select Toolpaths -> Surface Rough -> Rough Radial Toolpath... Mastercam X displays the Select Boss/Cavity dialog. ■ select Boss ■ select OK Mastercam X prompts for geometry. ■ select All...
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Chapter 2: Ring Gear
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■ select Entities (NOT All Entities) ■ select Surfaces by double-clicking it
Mastercam X closes the Select All window and selects all of the surfaces. ■ select End Selection Mastercam X displays the Toolpath/surface selection dialog. ■ select OK Mastercam X displays the Surface Rough Radial window. Use the same tool from the last toolpath: Set your Toolpath Parameters as shown in Figure 2.13.1.
Figure 2.13.1: Toolpath Parameters. Set your Surface Parameters as shown in Figure 2.13.2.
Figure 2.13.2: Surface Parameters.
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This book is to be distributed freely and may be copied or printed as needed.
Set your Rough Radial Parameters as shown in Figure 2.13.3.
Figure 2.13.3: Rough Radial Parameters. ■ select OK Mastercam X prompts for a radial point:
■ select Origin
Mastercam X creates the toolpath. Your drawing should look like Figure 2.13.4.
Figure 2.13.4: Rough radial toolpath. Save your drawing: ■ select File -> Save
Section 14: Gear Surface Finish Toolpath (4/5) Next, create a Finish Radial Toolpath to finish the gear surface. ■ select Toolpaths -> Surface Finish -> Finish Radial Toolpath...
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Chapter 2: Ring Gear
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Mastercam X prompts for geometry.
■ select All... ■ select Entities (NOT All Entities) ■ select Surfaces by double-clicking it Mastercam X closes the Select All window and selects all of the surfaces. ■ select End Selection Mastercam X displays the Toolpath/surface selection dialog. ■ select OK Mastercam X displays the Surface Finish Radial window. You will select a new tool for this operation: ■ select Select library tool... Mastercam X displays the Tool Selection dialog. ■ select #247 Endmill2 Sphere 0.0625" as shown in Figure 2.14.1
Figure 2.14.1: #249 1/16" endmill. ■ select OK
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This book is to be distributed freely and may be copied or printed as needed.
Set your Toolpath Parameters as shown in Figure 2.14.2.
Figure 2.14.2: Toolpath Parameters. Set your Surface Parameters as shown in Figure 2.14.3.
Figure 2.14.3: Surface Parameters.
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Chapter 2: Ring Gear
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Set your Finish Radial Parameters as shown in Figure 2.14.4.
Figure 2.14.4: Finish Radial Parameters. ■ select OK Mastercam X prompts for a radial point:
■ select Origin
Mastercam X creates the toolpath. Your drawing should look like Figure 2.14.5.
Figure 2.14.5: Finish radial toolpath. Save your drawing: ■ select File -> Save
Section 15: Outer Contour Toolpath (5/5) The final toolpath you will create is a Contour Toolpath that will cut away the stock around the outer edge of the gear. Turn toolpath display off:
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This book is to be distributed freely and may be copied or printed as needed. ■ select Select All Operations ■ select Toggle Toolpath Display Make the toolpath: ■ select Toolpaths -> Contour Toolpath... Mastercam X prompts for geometry. ■ select the upper circle as shown in Figure 2.15.1
Figure 2.15.1: Select this circle for the contour toolpath. ■ select OK Mastercam X displays the Contour (2D) dialog. Set the Toolpath Parameters as shown in Figure 2.15.2
Figure 2.15.2: Toolpath Parameters.
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Chapter 2: Ring Gear
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Fill out the Contour Parameters tab as shown in Figure 2.15.3.
Figure 2.15.3: Contour Parameters. ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 2.15.4.
Figure 2.15.4: Correctly toolpathed part. Save your drawing: ■ select File -> Save
Section 16: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1 Mastercam X displays the Verify Controller, changes your view to isometric and fits your part to screen.
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This book is to be distributed freely and may be copied or printed as needed. ■ select Simulate Tool ■ select Machine Mastercam X machines your part. You can control the speed and quality by adjusting the options in the Verify Controller. When your part is machined, it should look like Figure 2.16.1.
Figure 2.16.1: Verified gear assembly. If it does: ■ select OK Mastercam X exits verify mode.
Section 17: Post Processing This chapter contains 5 toolpaths using two different tools. If you have an automatic tool changer, or feel comfortable changing the tool mid-program, follow the directions to post all of the toolpaths as one file: In the Toolpaths tab on the left of the Mastercam X window: ■ select Select All Operations ■ select Post Selected Operations Mastercam X displays the Post Processing dialog. ■ select Select Post Mastercam X displays the Open dialog. ■ select the post that matches your machine ■ select Open
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Chapter 2: Ring Gear
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Match the other settings with those shown in Figure 2.17.1.
Figure 2.17.1: Post Processing. ■ select OK Mastercam X displays a Save dialog for you to save your NC file. In the File name field: ■ type RING plus your initials. Example: RINGNWT ■ select Save Mastercam X saves your NC file. You can use this to machine your part, if you want. If you do not, however, you can post the NC code in two separate files, one for each tool: ■ select the 1 - Pocket (Standard) toolpath Hold down CTRL to select the other toolpaths: ■ select the 2 - Pocket (Standard) toolpath ■ select the 3 - Surface Rough Radial toolpath ■ select the 5 - Contour (2D) toolpath Green checkmarks should appear in the folders next to the four toolpaths you selected. A green checkmark should not appear in the folder next to the 4 - Surface Finish Radial toolpath. ■ select Post Selected Operations Mastercam X displays the Post Processing dialog. ■ select Select Post Mastercam X displays the Open dialog. ■ select the post that matches your machine ■ select Open
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This book is to be distributed freely and may be copied or printed as needed.
Match the other settings with those shown in Figure 2.17.2.
Figure 2.17.2: Post Processing. ■ select OK Mastercam X warns that no all toolpaths were selected. ■ select No Mastercam X displays a Save dialog for you to save your NC file. In the File name field: ■ type RING1 plus your initials. Example: RING1NWT ■ select Save Mastercam X saves your NC file. It will use the 1/4" Flat Endmill. Now, create a separate post for the 1/16" Ball Endmill: ■ select the 4 - Surface Finish Radial toolpath A green checkmark should appear in only the folder next to 4 - Surface Finish Radial toolpath. ■ select Post Selected Operations Mastercam X displays the Post Processing dialog. ■ select Select Post Mastercam X displays the Open dialog. ■ select the post that matches your machine ■ select Open Match the other settings with those shown in Figure 2.17.3.
Figure 2.17.3: Post Processing. ■ select OK
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Chapter 2: Ring Gear
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Mastercam X warns that no all toolpaths were selected. ■ select No
Mastercam X displays a Save dialog for you to save your NC file. In the File name field: ■ type RING2 plus your initials. Example: RING2NWT ■ select Save Mastercam X saves your NC file. It will use the 1/16" Ball Endmill. If you machine your part, the best way to prepare the stock would be to use double-sided tape to attach two 1/2" pieces together. Finally, save your file: ■ select File -> Save Since you saved your file before, Mastercam X silently saves the changes you have made since then, without prompting again for a file name.
Congratulations! You have completed the Ring Gear Exercise!
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This book is to be distributed freely and may be copied or printed as needed.
Chapter
3 Geometry
Spider and Pinion Gears
➤ About this project:
Toolpath
Abstract Create a complex gear using surfaces.
Description The ring gear uses three surfaces to give it angle and taper. The gears are made by transforming and rotating a single tooth.
Materials 4"x3"x0.75" Protofoam Block.
Verified
Machines 1/8" Flat Endmill, 1/16" Ball Endmill
Functions Break Many Pieces, Rough Radial Toolpath
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Chapter 3: Spider and Pinion Gears
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Section 1: Setup Start Mastercam X. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X does not do this automatically. ■ select Machine Type -> Mill -> Your Machine If you have not created a Mastercam X Machine Definition for your machine, or if no machine is available, choose the default machine: ■ select Machine Type -> Mill -> 3 - Axis VMC.MMD Mastercam X creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Stock Setup Before creating the geometry, tell Mastercam X what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
■ select Stock Setup
Mastercam X displays the Stock Setup dialog. Set your parameters as shown in Figure 3.2.1:
Figure 3.2.1: Stock Setup dialog.
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This book is to be distributed freely and may be copied or printed as needed. ■ select OK
Section 3: Pinion Gear Geometry The first gear you will create is the pinion gear. First, however, you must create supporting geometry: Change your color to #11 cyan: ■ select the #10 green swatch in the bottom of the Mastercam X window Mastercam X displays the Colors dialog. In the current color field: ■ type 11 press ENTER ■ select OK Mastercam X sets the color to #11 cyan. Create the axle hole circles: ■ ■ ■ ■ ■
select Create -> Arc -> Create Circle Center Point... select Diameter type 0.255 press ENTER press SPACE type X3.5 Y1.5 press ENTER
Mastercam X creates the first gear. Create the second, directly below the first: ■ select Apply ■ press SPACE ■ type X3.5 Y1.5 Z-0.25 press ENTER Mastercam X has created two circles, one directly below the other. Thus, they will appear as one from top view. Your drawing should look like Figure 3.3.1.
Figure 3.3.1: Two circles that represent the axle hole for the pinion gear. Next, create a bounding circle that will be used to machine the area around the pinion gear. ■ ■ ■ ■ ■
press D type 1.0 press ENTER press SPACE type X3.5 Y1.5 Z-0.25 press ENTER select OK
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X creates the bounding circle. Your drawing should look like Figure 3.3.2.
Figure 3.3.2: Bounding circle for the pinion gear. Save your drawing: Since you are saving for the first time, Mastercam X displays the Save dialog. In the File name field: ■ type SPIDER plus your initials. Example: SPIDERNWT ■ select Save Mastercam X saves your file.
Section 4: Pinion Gear Now that the supporting geometry for the pinion gear is in place, create the two gears that will be used to make the pinion ear surface. ■ select Settings -> Run User Application... ■ - OR ■ press ALT-C Mastercam X displays the Open dialog. ■ select Gear.dll ■ select Open
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X displays the Gear dialog. Match your parameters with those shown in Figure 3.4.1. Pressing ENTER after setting the first few properties will calculate the others.
Figure 3.4.1: Parameters for first gear. ■ select OK Mastercam X creates the gear, centered at the origin. Next, translate the gear to the correct position: ■ select Xform -> Xform Translate... ■ select Chain
in the toolbar
Mastercam X will now select chains instead of individual geometry. ■ select anywhere on the gear ■ select End Selection Mastercam X displays the Translate dialog. ■ select Move ■ select Select FROM point ■ select Origin ■ press SPACE ■ type X3.5 Y1.5 Z-0.25 press ENTER ■ select OK
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Chapter 3: Spider and Pinion Gears
This book is to be distributed freely and may be copied or printed as needed.
Mastercam X translates the gear to the correct position. Your drawing should look like Figure 3.4.2.
Figure 3.4.2: Translated base pinion gear. Mastercam X create the second gear: ■ select Settings -> Run User Application... ■ - OR ■ press ALT-C Mastercam X displays the Open dialog. ■ select Gear.dll ■ select Open Mastercam X displays the Gear dialog. Match your parameters with those shown in Figure 3.4.3. Pressing ENTER after setting the first few properties will calculate the others.
Figure 3.4.3: Parameters for second gear. ■ select OK Mastercam X creates the gear, centered at the origin. Next, translate the gear to the correct position:
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This book is to be distributed freely and may be copied or printed as needed.
■ select Xform -> Xform Translate...
Mastercam X will now select chains instead of individual geometry. ■ select anywhere on the cyan gear ■ select End Selection Mastercam X displays the Translate dialog. ■ select Move ■ select Select FROM point ■ select Origin ■ press SPACE ■ type X3.5 Y1.5 press ENTER ■ select OK Mastercam X translates the gear to the correct position. Change your Gview to Isometric: ■ press ALT-7 ■ press ALT-F1 Your drawing should look like Figure 3.4.4.
Figure 3.4.4: Translated top pinion gear. Return to normal selection mode: ■ select Standard Selection
in the toolbar
Save your drawing: ■ select File -> Save
Section 5: Pinion Gear Surfaces Now that the geometry for the pinion gear is complete, create surfaces that you can toolpath later: ■ select Create -> Surface -> Create Ruled / Lofted Surfaces... Mastercam X displays the Chaining window and prompts for geometry.
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■ select the two circles shown in Figure 3.5.1
Figure 3.5.1: Select these two circles for the axle wall surface. ■ select OK ■ select OK Mastercam X creates the surface. Your drawing should look like Figure 3.5.2.
Figure 3.5.2: Axle wall surface. Change your Gview to Top: ■ press ALT-1 ■ press ALT-F1 Create the pinion gear surface: ■ select Create -> Surface -> Create Ruled / Lofted Surfaces... Mastercam X displays the Chaining window and prompts for geometry.
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This book is to be distributed freely and may be copied or printed as needed.
■ select exactly as shown in Figure 3.5.3
Figure 3.5.3: Selection for pinion gear surface. ■ select OK ■ select OK Mastercam X creates the pinion gear surface. It should be straight as shown in Figure 3.5.4. If it is twisted, delete it and create it again.
Figure 3.5.4: Pinion gear surface. Change your Gview to Isomtric and turn shading on: ■ press ALT-7 ■ press ALT-F1 ■ select Shaded
in the toolbar
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Your drawing should look like Figure 3.5.5.
Figure 3.5.5: Shaded pinion gear surface. There are two more surfaces you must create for the pinion gear. ■ select Create -> Surface -> Create Flat Boundary Surface... Mastercam X displays the chaining window and prompts for geometry. ■ select anywhere on the large outer circle ■ select OK ■ select Apply Mastercam X creates a flat boundary surface at the base of the gear, and prompts for more geometry. Create the final surface: ■ select the gear and axle circle as shown in Figure 3.5.6
Figure 3.5.6: Selection for top pinion flat boundary surface. ■ select OK ■ select OK
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This book is to be distributed freely and may be copied or printed as needed.
Your drawing should look like Figure 3.5.7.
Figure 3.5.7: Completed pinion gear. Save your drawing: ■ select File -> Save
Section 6: Spider Gear Geometry The second gear you will create is a spider gear. Change your Gview to Top: ■ press ALT-1 ■ press ALT-F1 Change to the #4 dark red color: ■ select the #11 cyan swatch at the bottom of the Mastercam X window Mastercam X displays the Colors dialog. In the color field: ■ type 4 press ENTER ■ select OK All geometry will be created in the #4 dark red color. Create the supporting geometry: ■ ■ ■ ■ ■
select Create -> Arc -> Create Circle Center Point... select Diameter type 0.255 press ENTER press SPACE type X0.75 Y0.75 press ENTER
Mastercam X creates the first circle. Create a second directly below the first: ■ ■ ■ ■
select Apply press SPACE type X0.75 Y0.75 Z-0.25 press ENTER select OK
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Chapter 3: Spider and Pinion Gears
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Mastercam X creates the second circle directly below the first. It will appear as one circle in Top view. Your drawing should look like Figure 3.6.1.
Figure 3.6.1: Axle hole circles for the spider gear. Next, create three more circles: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
select Create -> Arc -> Create Circle Center Point... press D type 1.5 press ENTER press SPACE type X0.75 Y0.75 Z-0.25 press ENTER select Apply press D type 1.0 press ENTER press SPACE type X0.75 Y0.75 Z-0.25 press ENTER select Apply press D type 0.5 press ENTER press SPACE type X0.75 Y0.75 press ENTER select OK
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X creates the three circles. Your drawing should look like Figure 3.6.2.
Figure 3.6.2: Circles for the spider gear. Save your drawing: ■ select File -> Save
Section 7: Spider Gears Now that the supporting geometry is complete, create the actual teeth for the spider gear: ■ select Settings -> Run User Application... ■ - OR ■ press ALT-C Mastercam X displays the Open dialog. ■ select Gear.dll ■ select Open
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Chapter 3: Spider and Pinion Gears
This book is to be distributed freely and may be copied or printed as needed.
Mastercam X displays the Gear dialog. Match your parameters with those shown in Figure 3.7.1. Pressing ENTER after setting the first few properties will calculate the others.
Figure 3.7.1: Parameters for first tooth. ■ select OK Mastercam X creates the tooth, centered at the origin. Next, translate the tooth to the correct position: ■ select Xform -> Xform Translate... ■ select Chain
in the toolbar
Mastercam X will now select chains instead of individual geometry. ■ select anywhere on the dark red tooth ■ select End Selection Mastercam X displays the Translate dialog. ■ select Move ■ select Select FROM point ■ select Origin ■ press SPACE ■ type X0.75 Y0.75 Z-0.25 press ENTER ■ select OK
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X translates the tooth to the correct position. Your drawing should look like Figure 3.7.2.
Figure 3.7.2: Translated spider gear tooth. Mastercam X create the second tooth: ■ select Settings -> Run User Application... ■ - OR ■ press ALT-C Mastercam X displays the Open dialog. ■ select Gear.dll ■ select Open Mastercam X displays the Gear dialog. Match your parameters with those shown in Figure 3.7.3. Pressing ENTER after setting the first few properties will calculate the others.
Figure 3.7.3: Parameters for second tooth. ■ select OK Mastercam X creates the tooth, centered at the origin. Next, translate the gear to the correct position:
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This book is to be distributed freely and may be copied or printed as needed.
■ select Xform -> Xform Translate... ■ select Chain
in the toolbar
Mastercam X will now select chains instead of individual geometry. ■ select anywhere on the dark red tooth at the left of the drawing ■ select End Selection Mastercam X displays the Translate dialog. ■ select Move ■ select Select FROM point ■ select Origin ■ press SPACE ■ type X0.75 Y0.75 press ENTER ■ select OK Mastercam X translates the tooth to the correct position. Your drawing should look like Figure 3.7.4.
Figure 3.7.4: Translated top spider gear. Return to normal selection mode: ■ select Standard Selection
in the toolbar
Next, the teeth must be rotated as they were in the Ring chapter. Points at the intersection must be created first. Change your Gview to Isometric: ■ press ALT-7 ■ press ALT-F1 ■ press F1
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This book is to be distributed freely and may be copied or printed as needed.
Drag a zoom window around the top tooth as shown in Figure 3.7.5.
Figure 3.7.5: Zoom rectangle for the top spider gear. You may have to zoom in twice, due to the relitive size of the tooth and the stock. Make sure that the two teeth and the two circles are the only entities on the screen. Create the point: ■ select Create -> Point -> Create Point Position... You will use the autocursor to select the intersection of the tooth and the circle. When you move the mouse onto the intersection, Mastercam X adds a small X to the cursor to show that it will create the point at that intersection. ■ select the intersection of the purple tooth and dark red circle ■ select the intersection of the dark red tooth and the dark red circle as shown in Figure 3.7.6
Figure 3.7.6: Create points at these two intersections.
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This book is to be distributed freely and may be copied or printed as needed.
The points are dark and difficult to see, but Mastercam X did create them. They should look as shown in Figure 3.7.7:
Figure 3.7.7: Points for spider gear rotation. Change your Cplane to Right Side: ■ select Planes -> Right Side (WCS) at the bottom of the Mastercam X window Rotate the first tooth: ■ select Xform -> Xform Rotate... ■ select Chain
in the toolbar
■ select anywhere on the top purple tooth ■ select End Selection Mastercam X displays the Rotate dialog. ■ select Move ■ select Define Center Mastercam X prompts for a center point. Use point selection mode to select the point:
■ select Point
Mastercam X will only select points.
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This book is to be distributed freely and may be copied or printed as needed.
■ select the intersection point shown in Figure 3.7.8
Figure 3.7.8: Select this intersection for the rotation point. In the angle field: ■ type 45.0 press ENTER Confirm the rotation: ■ select OK Your drawing should look like Figure 3.7.9.
Figure 3.7.9: First spider gear tooth rotated. Next, rotate the second tooth: ■ select Xform -> Xform Rotate... ■ select anywhere on the large brown bottom tooth ■ select End Selection Mastercam X displays the Rotate dialog. Define a center point of rotation: ■ select Define Center
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Chapter 3: Spider and Pinion Gears
This book is to be distributed freely and may be copied or printed as needed.
Mastercam X prompts for a center point. Use point selection mode to select the point:
■ select Point
Mastercam X will only select points. ■ select the intersection point shown in Figure 3.7.10
Figure 3.7.10: Select this intersection for the rotation point. In the angle field: ■ type 45.0 press ENTER Confirm the rotation: ■ select OK
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This book is to be distributed freely and may be copied or printed as needed.
Your drawing should look like Figure 3.7.11.
Figure 3.7.11: Second spider gear tooth rotated. Finally, rotate the teeth around the axle to create the two gears. First, change your Cplane to Top: ■ select Planes -> Top (WCS) ■ press F2 ■ press F2 Next, do the rotation: ■ select Xform -> Xform Rotate... Mastercam X prompts for geometry to rotate: ■ select anywhere on the smaller top tooth ■ select anywhere on the larger bottom tooth ■ select End Selection Mastercam X displays the Rotate dialog. ■ select Copy ■ select Define Center ■ select Arc Center
Mastercam X will select only arcs. ■ select any one of the circles around the spider gear teeth This works because the center points of all 5 gears have the same X and Y values. In the number field: ■ type 9 press ENTER In the angle field: ■ type 360/10 press ENTER Confirm the rotation: ■ select OK
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Chapter 3: Spider and Pinion Gears
This book is to be distributed freely and may be copied or printed as needed.
Mastercam X rotates the gears. Your drawing should look like Figure 3.7.12.
Figure 3.7.12: Spider gears created by rotating the teeth. You will notice a gap between each of the teeth. Fill this with a line. First, change your Gview and Cplane to top: ■ ■ ■ ■
press ALT-1 press ALT-F1 press F1 select Standard Selection
in the toolbar
Mastercam X prompts for a zoom rectangle. Drag a zoom rectangle as shown in Figure 3.7.13.
Figure 3.7.13: Zoom here. Create a line to patch the gap: ■ select Create -> Line -> Create Line Endpoint...
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This book is to be distributed freely and may be copied or printed as needed.
■ select as shown in Figure 3.7.14
Figure 3.7.14: Select these four points. ■ select OK Rotate these lines to close the other gaps: ■ ■ ■ ■
press F2 select Xform -> Xform Rotate... select the two lines you just created select End Selection
Mastercam X displays the Rotate dialog. ■ select Copy Define a center point: ■ select Define Center ■ select Arc Center
Mastercam X will select only arcs. ■ select any one of the circles around the spider gear teeth In the number field: ■ type 9 press ENTER In the angle field: ■ type 360/10 press ENTER Confirm the rotation: ■ select OK Mastercam X rotates the filler line around to the other teeth. There is one final step for the spider gear geometry: break the filler line on the right most small gear into two pieces. ■ select Edit -> Trim / Break -> Break many pieces ■ press N ■ type 2 press ENTER
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Chapter 3: Spider and Pinion Gears
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Mastercam X prompts for a line.
■ select the red line as shown in Figure 3.7.15
Figure 3.7.15: Select this line to break it into two pieces. ■ select OK Mastercam X breaks the line, but remains the same in your drawing. Save your drawing: ■ select File -> Save
Section 8: Spider Gear Surfaces Now that the spider gear geometry is complete, create the spider gear surfaces: ■ press ALT-UP ARROW ■ select Create -> Surface -> Create Ruled / Lofted Surfaces... Mastercam X prompts for contours. ■ select the gear and circle as shown in Figure 3.8.1
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This book is to be distributed freely and may be copied or printed as needed.
On the gear, you are selecting the lower end of the top red filler line you split. It is important to make sure that both of the selection arrows point the same direction. When you select the gear, memorize the direction of the arrow. When you select the circle, if the arrow does not face the same way, reverse it.
Figure 3.8.1: Select these two contours. ■ select OK Mastercam X may warn about sharp corners. If so: ■ select Apply ■ press F2 ■ press F2 Mastercam X creates the surface. Your drawing should look like Figure 3.8.2.
Figure 3.8.2: First spider gear surface. Create the second surface: ■ select the two lines as shown in Figure 3.8.3.
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Chapter 3: Spider and Pinion Gears
This book is to be distributed freely and may be copied or printed as needed.
It is important that both of the direction arrows point the same direction. When you select the first line, memorize the direction of the direction arrow. If, when you select the second line, the direction arrow does not point the same way, reverse it.
Figure 3.8.3: Select these two lines. ■ select OK Mastercam X creates a preview of the surface. ■ select OK Your drawing should look like Figure 3.8.4.
Figure 3.8.4: Second spider surface. Create the third: ■ ■ ■ ■
press F2 select Create -> Surface -> Create Flat Boundary Surface... select the large outer circle select OK
■ select OK Mastercam X creates the surface. Change your Gview to Isometric:
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This book is to be distributed freely and may be copied or printed as needed.
■ press ALT-7 ■ press F2
Your drawing should look like Figure 3.8.5.
Figure 3.8.5: Completed spider gear surfaces. Save your drawing: ■ select File -> Save
Section 9: Pinion Gear Toolpaths The pinion gear will have three toolpaths: Pocket axle hole, Surface Rough and Surface Finish. Create the pocket now: ■ select Toolpaths -> Pocket Toolpath... ■ press ALT-F1 ■ press F1 Drag a zoom window around the blue pinion gear. ■ select the circle as shown in Figure 3.9.1.
Figure 3.9.1: Select this circle Mastercam X displays the Pocketing (Standard) window. Select a tool: ■ select Select library tool... Mastercam X displays the Tool Selection dialog.
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■ select #232 Endmill1 Flat 0.125" as shown in Figure 3.9.2
Figure 3.9.2: #232 1/8" endmill. ■ select OK Set your Toolpath Parameters as shown in Figure 3.9.3.
Figure 3.9.3: Toolpath Parameters.
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This book is to be distributed freely and may be copied or printed as needed.
Set your Pocketing Parameters as shown in Figure 3.9.4.
Figure 3.9.4: Pocketing Parameters. ■ select Depth cuts... Mastercam X displays the Depth cuts window. Set your parameters as shown in Figure 3.9.5.
Figure 3.9.5: Depth cut parameters. ■ select OK Set your Roughing/Finishing Parameters as shown in Figure 3.9.6.
Figure 3.9.6: Roughing/Finishing Parameters.
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This book is to be distributed freely and may be copied or printed as needed.
■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 3.9.7.
Figure 3.9.7: A pocket toolpath. Next, create the surface rough toolpath: ■ select Toolpaths -> Surface Rough -> Rough Radial Toolpath... Mastercam X displays the Select Boss/Cavity dialog. ■ select Boss ■ select OK Mastercam X prompts for geometry to toolpath. Drag a selection window around the entire pinion gear. ■ select End Selection Mastercam X displays the Toolapth/surface selection dialog. ■ select OK Mastercam X displays the Surface Rough Radial window. Use the same tool as the pocket toolpath: Set your Toolpath Parameters as shown in Figure 3.9.8.
Figure 3.9.8: Toolpath Parameters.
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This book is to be distributed freely and may be copied or printed as needed.
Set your Surface Parameters as shown in Figure 3.9.9.
Figure 3.9.9: Surface Parameters. Set your Rough Radial Parameters as shown in Figure 3.9.10.
Figure 3.9.10: Rough Radial Parameters. ■ select OK Mastercam X prompts for a radial point.
■ select Arc Center ■ select the circle you selected for the pocket toolpath
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X creates the toolpath. Your drawing should look like Figure 3.9.11.
Figure 3.9.11: Rough radial toolpath. Finally, create the finish toolpath: ■ select Toolpath -> Surface Finish -> Finish Radial Toolpath... Turn off toolpath display: ■ select Select All Operations ■ select Toggle Toolpath Display Mastercam X prompts for geometry to toolpath. Drag a selection window around the entire pinion gear. ■ select End Selection Mastercam X displays the Toolapth/surface selection dialog. ■ select OK Mastercam X displays the Surface Finish Radial window. You will need to select a new tool: ■ select Select library tool... Mastercam X displays the Tool Selection dialog. ■ select #247 Endmill2 Sphere 0.0625" as shown in Figure 3.9.12
Figure 3.9.12: #247 1/16" endmill.
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This book is to be distributed freely and may be copied or printed as needed. ■ select OK Set your Toolpath Parameters as shown in Figure 3.9.13.
Figure 3.9.13: Toolpath Parameters. Set your Surface Parameters as shown in Figure 3.9.14.
Figure 3.9.14: Surface Parameters.
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Chapter 3: Spider and Pinion Gears
This book is to be distributed freely and may be copied or printed as needed.
Set your Finish Radial Parameters as shown in Figure 3.9.15.
Figure 3.9.15: Rough Radial Parameters. ■ select OK Mastercam X prompts for a radial point.
■ select Arc Center ■ select the circle you selected for the pocket toolpath Mastercam X creates the toolpath. Turn on the other toolpaths: ■ select Select All Operations ■ select Toggle Toolpath Display Your drawing should look like Figure 3.9.16.
Figure 3.9.16: Pinion toolpaths. Save your drawing: ■ select File -> Save
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This book is to be distributed freely and may be copied or printed as needed.
Section 10: Spider Gear Toolpaths The spider gear will have three toolpaths: Pocket axle hole, Surface Rough and Surface Finish. Create the pocket now: ■ select Toolpaths -> Pocket Toolpath... ■ press ALT-F1 ■ press F1 Drag a zoom window around the red spider gear. ■ select the circle as shown in Figure 3.10.1.
Figure 3.10.1: Select this circle Mastercam X displays the Pocketing (Standard) window. Set your Toolpath Parameters as shown in Figure 3.10.2.
Figure 3.10.2: Toolpath Parameters. Set your Pocketing Parameters as shown in Figure 3.10.3.
Figure 3.10.3: Pocketing Parameters.
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■ select Depth cuts...
Mastercam X displays the Depth cuts window. Set your parameters as shown in Figure 3.10.4.
Figure 3.10.4: Depth cut parameters. ■ select OK Set your Roughing/Finishing Parameters as shown in Figure 3.10.5.
Figure 3.10.5: Roughing/Finishing Parameters. ■ select OK
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X creates the toolpath. Your drawing should look like Figure 3.10.6.
Figure 3.10.6: A pocket toolpath. Next, create the surface rough toolpath: ■ select Toolpaths -> Surface Rough -> Rough Radial Toolpath... Mastercam X displays the Select Boss/Cavity dialog. ■ select Boss ■ select OK Mastercam X prompts for geometry to toolpath. Drag a selection window around the entire spider gear. ■ select End Selection Mastercam X displays the Toolapth/surface selection dialog. ■ select OK Mastercam X displays the Surface Rough Radial window. Use the same tool as the pocket toolpath: Set your Toolpath Parameters as shown in Figure 3.10.7.
Figure 3.10.7: Toolpath Parameters.
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Set your Surface Parameters as shown in Figure 3.10.8.
Figure 3.10.8: Surface Parameters. Set your Rough Radial Parameters as shown in Figure 3.10.9.
Figure 3.10.9: Rough Radial Parameters. ■ select Cut depths...
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This book is to be distributed freely and may be copied or printed as needed.
Mastercam X displays the Cut Depths window. Set your parameters as shown in Figure 3.10.10.
Figure 3.10.10: ■ select OK ■ select OK Mastercam X prompts for a radial point.
■ select Arc Center ■ select the circle you selected for the pocket toolpath Mastercam X creates the toolpath. Your drawing should look like Figure 3.10.11.
Figure 3.10.11: Rough radial toolpath. Finally, create the finish toolpath: ■ select Toolpath -> Surface Finish -> Finish Radial Toolpath... Turn off toolpath display: ■ select Select All Operations ■ select Toggle Toolpath Display Mastercam X prompts for geometry to toolpath. Drag a selection window around the entire spider gear.
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■ select End Selection Mastercam X displays the Toolapth/surface selection dialog. ■ select OK Mastercam X displays the Surface Finish Radial window. Set your Toolpath Parameters as shown in Figure 3.10.12.
Figure 3.10.12: Toolpath Parameters. Set your Surface Parameters as shown in Figure 3.10.13.
Figure 3.10.13: Surface Parameters.
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This book is to be distributed freely and may be copied or printed as needed.
Set your Finish Radial Parameters as shown in Figure 3.10.14.
Figure 3.10.14: Rough Radial Parameters. ■ select OK Mastercam X prompts for a radial point.
■ select Arc Center ■ select the circle you selected for the pocket toolpath Mastercam X creates the toolpath. Turn on the other toolpaths: ■ select Select All Operations ■ select Toggle Toolpath Display Your drawing should look like Figure 3.10.15.
Figure 3.10.15: Spider toolpaths. Save your drawing: ■ select File -> Save
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Section 11: Toolpath Cleanup First, name your toolpaths: ■ select the 1 - Pocket (Standard) toolpath in the toolpaths tab After highlighting it, click it again. Mastercam X will create a field where you can enter a name for the toolpath. ■ type Pinion Pocket press ENTER Mastercam X names the first toolpath. Repeat this for the other toolpaths, until your toolpaths tab looks as follows:
Figure 3.11.1: Named toolpaths. Next, group your toopaths. You will create one group for the toolpaths using the 1/8" tool, and another for the toolpaths using the 1/16" tool. ■ select Machine Group 1 by right-clicking on it Mastercam X displays the context menu. ■ select Groups -> New Toolpath group Mastercam X creates a new toolpath group below the first and allows you to edit the name. ■ type 1/16" Toolpaths press ENTER Mastercam X names the second toolpath group. Rename the first: ■ select Toolpath Group 1 by right-clicking on it ■ select Groups -> Rename Mastercam X allows you to edit the name of the toolpath group. ■ type 1/8" Toolpaths press ENTER Mastercam X renames the first toolpath group. Next, move the 1/16" toolpaths into the 1/16" Toolpaths group.
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This book is to be distributed freely and may be copied or printed as needed.
■ select the Pinion Finish toolpath
Drag the toolpath to the 1/16" Toolpaths group by clicking and holding on it, then moving it onto the 1/16" group until the group highlights. Release the mouse to move the toolpath. Repeat with the Spider Finish toolpath. When you are finished, your groups should look like Figure 3.11.2.
Figure 3.11.2: Moved toolpaths. Save your drawing: ■ select File -> Save
Section 12: 1/8" Toolpath Array In order to cut out the four spider gears you need for the final assembly, you can create a toolpath array to avoid retoolpathing copied geometry. First, you will create an array with the spider gear's two 1/8" toolpaths. Right click on the 1/8" Toolpaths item in the toolpaths tab. ■ select Mill Toolpaths -> Transform
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Mastercam X displays the Transform Operations Parameters dialog. Set the Type and Methods parameters as shown in Figure 3.12.1. Hold CTRL to select multiple toolpaths.
Figure 3.12.1: Types and Methods for 1/8" toolpaths. Set your Translate parameters as shown in Figure 3.12.2.
Figure 3.12.2: Translate parameters for 1/8" toolpaths. ■ select OK ■ press ALT-F1
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Mastercam X creates the toolpath array. Your drawing should look like Figure 3.12.3.
Figure 3.12.3: 1/8" toolpath array.
Section 13: 1/16" Toolpath Array Next, create a second transform for the 1/16" inch toolpaths: Right click on the 1/16" Toolpaths item in the toolpaths tab. ■ select Mill Toolpaths -> Transform Mastercam X displays the Transform Operations Parameters dialog. Set the Type and Methods parameters as shown in Figure 3.13.1. Hold CTRL to select multiple toolpaths.
Figure 3.13.1: Types and Methods for 1/16" toolpaths.
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Chapter 3: Spider and Pinion Gears
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Set your Translate parameters as shown in Figure 3.13.2.
Figure 3.13.2: Translate parameters for 1/16" toolpaths. ■ select OK ■ press ALT-F1 Mastercam X creates the toolpath array. Your drawing should look like Figure 3.13.3.
Figure 3.13.3: 1/16" toolpath array.
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Finally, move the two transform toolpaths to their respective groups. By dragging the toolpaths into groups as you did before, set your toolpaths tab as shown in Figure 3.13.4.
Figure 3.13.4: Properly grouped toolpaths. Save your drawing: ■ select File -> Save
Section 14: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1 Mastercam X displays the Verify Controller, changes your view to isometric and fits your part to screen. ■ select Simulate Tool ■ select Machine Mastercam X machines your part. You can control the speed and quality by adjusting the options in the Verify Controller.
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Chapter 3: Spider and Pinion Gears
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When your part is machined, it should look like Figure 3.14.1.
Figure 3.14.1: Verified spider and pinion gears. If it does: ■ select OK Mastercam X exits verify mode.
Section 15: Post Processing The toolpaths in this chapter are already broken into groups by tool, making it easier to post: In the Toolpaths tab on the left of the Mastercam X window: ■ select the 1/8" Toolpaths group ■ select Post Selected Operations Mastercam X displays the Post Processing dialog. Match the other settings with those shown in Figure 3.15.1.
Figure 3.15.1: Post Processing. ■ select OK Mastercam X warns that no all toolpaths were selected. ■ select No Mastercam X displays a Save dialog for you to save your NC file. In the File name field:
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■ type SPIDER1 plus your initials. Example: SPIDER1NWT ■ select Save
Mastercam X saves your NC file. This will machine the Rough and Pocket toolpaths on both the Pinion and Spider gears. Post the 1/16" toolpaths: ■ select the 1/16" Toolpaths group ■ select Post Selected Operations Match your settings with those shown in Figure 3.15.2.
Figure 3.15.2: Post Processing. ■ select OK Mastercam X warns that no all toolpaths were selected. ■ select No Mastercam X displays a Save dialog for you to save your NC file. In the File name field: ■ type SPIDER2 plus your initials. Example: SPIDER2NWT ■ select Save Mastercam X saves your NC file. This will machine the Finish toolpaths on both the Pinion and Spider gears. Finally, save your file: ■ select File -> Save Since you saved your file before, Mastercam X silently saves the changes you have made since then, without prompting again for a file name.
Congratulations! You have completed the Ring Gear Exercise!
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Chapter
4 Geometry
Axle Housing Toolpath ➤ About this project:
Abstract Create axle housings using a lathe.
Verified
Description The axle housings will connect to the frame and hold the axles in place.
Materials (3) 1" Diameter, 4" in length Acrylic rod.
Machines R0.0156 OD FINISH RIGHT, .25" Diameter Drill, R0.01 W0.125 OD GROOVE CENTER.
Functions Lathe Rough Toolpath, Lathe Finish Toolpath, Lathe Drill Toolpath, Lathe Groove Toolpath, Lathe Cutoff Toolpath
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Chapter 4: Axle Housing
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Section 1: Setup Start Mastercam X. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X does not do this automatically. ■ select Machine Type -> Lathe -> Lathe Default.LMD Mastercam X creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Geometry First, set your Cplane to +D+ Z: ■ select Planes -> Lathe Diameter -> +D +Z Next, create a profile of the part using lines: ■ select Create -> Line -> Create Line Endpoint... ■ select Multi-line Enter the following coordinates to create the profile: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
press SPACE type D0 Z0 press ENTER press SPACE type D0.5 Z0 press ENTER press SPACE type D1 Z-1.875 press ENTER press SPACE type D0.874 press ENTER press SPACE type D0.874 Z-2.125 press ENTER select OK
Mastercam X creates the profile lines. Zoom appropriately: ■ press ALT-F1 ■ press F2 Your drawing should look like Figure 4.2.1.
Figure 4.2.1: Completed axle housing geometry. Save your drawing: Since you are saving for the first time, Mastercam X displays the Save dialog. In the File name field: ■ type HOUSING plus your initials. Example: HOUSINGNWT ■ select Save Mastercam X saves your file.
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Section 3: Rough Toolpath The axle housing will be machined using 5 toolpaths, to get a good finish. Stock setup is not necessary because the geometry reaches the outer limit of the stock. ■ select Toolpaths -> Lathe Rough Toolpath... Mastercam X prompts for geometry to toolpath. ■ select the two lines as shown in Figure 4.3.1
Figure 4.3.1: Rough toolpath selection. ■ select OK Mastercam X displays the Lathe Rough Parameters dialog. Set your Toolpath Parameters as shown in Figure 4.3.2.
Figure 4.3.2: Toolpath Parameters. In the Home Position box: ■ select User Defined in the drop down menu ■ select Define Mastercam X displays the Home Position window. Set your parameters as shown in Figure 4.3.3.
Figure 4.3.3: Home position.
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Chapter 4: Axle Housing
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■ select OK Set your Rough Parameters as shown in Figure 4.3.4.
Figure 4.3.4: Rough Parameters. ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 4.3.5.
Figure 4.3.5: Rough toolpath.
Section 4: Finish Toolpath The next toolpath to create is the finish toolpath. ■ select Toolpaths -> Lathe Finish Toolpath... ■ select Last ■ select OK Mastercam X displays the Lathe Finish Properties window.
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Set your Toolpath Parameters as shown in Figure 4.4.1.
Figure 4.4.1: Toolpath Parameters. In the Home Position box: ■ select User Defined in the drop down menu ■ select Define Mastercam X displays the Home Position window. Set your parameters as shown in Figure 4.4.2.
Figure 4.4.2: Home position. ■ select OK
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Chapter 4: Axle Housing
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Set your Finish Parameters as shown in Figure 4.4.3.
Figure 4.4.3: Finish Parameters. ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 4.4.4.
Figure 4.4.4: Finish toolpath. Save your drawing: ■ select File -> Save
Section 5: Drill Toolpath Next, create a drill toolpath to drill a hole down the center of the part.The axle will fit through this hole. ■ select Toolpaths -> Lathe Drill Toolpath... Mastercam X displays the Lathe Drill Properties dialog.
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Set your Toolpath Parameters as shown in Figure 4.5.1.
Figure 4.5.1: Toolpath Parameters. Right click on the selected tool: ■ select Edit Tool... Mastercam X displays the Define Tool window. Set your Tool Geometry settings as shown in Figure 4.5.2.
Figure 4.5.2: Tool geometry settings. ■ select OK
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Chapter 4: Axle Housing
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Set your Peck Drill (Simple Drill) parameters as shown in Figure 4.5.3.
Figure 4.5.3: Peck drill parameters. ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 4.5.4.
Figure 4.5.4: Drill toolpath.
Section 6: Groove Toolpath The groove toolpath will cut the notch in the axle housing. Turn toolpath display off: ■ select Select All Operations ■ select Toggle Toolpath Display Create the toolpath: ■ select Toolpaths -> Lathe Groove Toolpath... ■ select 2 Points ■ select OK Mastercam X prompts for two points to create the groove toolpath. ■ select the two points as shown in Figure 4.6.1
Figure 4.6.1: Groove point selection.
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■ press ENTER
Mastercam X displays the Lathe Groove Properties dialog. Set your Toolpath Parameters as shown in Figure 4.6.2.
Figure 4.6.2: Toolpath Parameters. In the Home Position box: ■ select User Defined in the drop down menu ■ select Define Mastercam X displays the Home Position window. Set your parameters as shown in Figure 4.6.3.
Figure 4.6.3: Home position. ■ select OK The default parameters for the other three tabs will create the toolpath as desired. ■ select OK Mastercam X creates the toolpath. Turn toolpath display on: ■ select Select All Operations ■ select Toggle Toolpath Display Your drawing should look like Figure 4.6.4.
Figure 4.6.4: Groove toolpath.
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Chapter 4: Axle Housing
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Save your drawing:
■ select File -> Save
Section 7: Cutoff Toolpath The final toolpath is a cutoff toolpath that will cut the axle housing off from the remaining stock. Turn toolpath display off: ■ select Select All Operations ■ select Toggle Toolpath Display Create the toolpath: ■ select Toolpaths -> Lathe Cutoff Toolpath... Mastercam X prompts for a cutoff boundary point. ■ select the leftmost endpoint as shown in Figure 4.7.1
Figure 4.7.1: Selection for cutoff toolpath. Mastercam X displays the Lathe Cutoff Properties dialog. Set your Toolpath Parameters as shown in Figure 4.7.2.
Figure 4.7.2: Toolpath Parameters. In the Home Position box: ■ select User Defined in the drop down menu ■ select Define
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Mastercam X displays the Home Position window. Set your parameters as shown in Figure 4.7.3.
Figure 4.7.3: Home position. Set your Cutoff Parameters as shown in Figure 4.7.4.
Figure 4.7.4: Cutoff Parameters. ■ select OK Mastercam X creates the cutoff toolpath. Turn toolpath display on: ■ select Select All Operations ■ select Toggle Toolpath Display Your drawing should look like Figure 4.7.5.
Figure 4.7.5: Cutoff toolpath.
Section 8: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1
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Chapter 4: Axle Housing
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Mastercam X displays the Verify Controller, changes your view to isometric and fits your part to screen. ■ select Simulate Tool ■ select Machine
Mastercam X machines your part. You can control the speed and quality by adjusting the options in the Verify Controller. When your part is machined, it should look like Figure 4.8.1.
Figure 4.8.1: Verified axle housing. Now, remove a section from your part to see the inside: ■ select Stock Section ■ select Stock Section ■ select Stock Section 3/4 of your part will be displayed. You can use dynamic rotation to see the inside. When rotated, your figure should look like Figure 4.8.2.
Figure 4.8.2: View the inside of the axle housing. When you are done viewing your part: ■ select OK
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Mastercam X exits verify mode.
Section 9: Post Processing The toolpaths in this chapter are already broken into groups by tool, making it easier to post: In the Toolpaths tab on the left of the Mastercam X window: ■ select Select All Operations ■ select Post Selected Operations Mastercam X displays the Post Processing dialog. Match the other settings with those shown in Figure 4.9.1.
Figure 4.9.1: Post Processing. ■ select OK Mastercam X displays a Save dialog for you to save your NC file. In the File name field: ■ type HOUSING plus your initials. Example: HOUSINGNWT ■ select Save Mastercam X saves your NC file. Save your drawing: ■ select File -> Save
Congratulations! You have completed the Ring Gear Exercise!
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Chapter 4: Axle Housing
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Section 10: Optional Drive Shaft Housing For the assembly, 2 axle housings and 1 drive shaft housing are needed. You can either machine 3 axle housings, and use one as the drive housing, or make an alternate drive housing using the methods learned in this chapter and the schematic in Figure 4.10.1.
Figure 4.10.1: Alternate drive housing.
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Chapter
5 Geometry
Spider Gear Carrier
➤ About this project:
Abstract Create a carrier housing that.
Toolpath
Description Using a drill press and a CNC mill, create a carrier that will hold the hold the spider gears in the final assembly.
Materials 2"x2"x0.5" Acrylic.
Machines 1/4" Flat Endmill.
Verified
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Chapter 5: Spider Gear Carrier
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Section 1: Setup Start Mastercam X. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X does not do this automatically. ■ select Machine Type -> Mill -> Mill 3 - Axis VMC.MMD Mastercam X creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Preparation Before you can machine this part, you must use a drill press to drill holes in your stock, per the schematic in Figure 5.2.1.
Figure 5.2.1: Drill locations. The holes should be drilled as follows: Left Side: 1/4" hole, 3/8" deep, centered on the side (1/4" from the top) Back Side: 1/4" hole, 3/8" deep, centered on the side (1/4" from the top) Right Side: 1/4" hole, 3/8" deep, centered on the side (1/4" from the top)
Section 3: Geometry First, create the carrier geometry: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
select Create -> Create Rectangle... press SPACE type X0.125 Y0.39 press ENTER press SPACE type X1.875 Y1.875 press ENTER select Apply press SPACE type X0.375 Y0.45 press ENTER press SPACE type X1.625 Y1.625 press ENTER select OK
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Mastercam X creates the two rectangles. ■ press ALT-F1 ■ press F2
Your drawing should look like Figure 5.3.1.
Figure 5.3.1: Two rectangles. Next, trim the sides of the inner rectangles to the bottom of the outer rectangles: ■ select Edit -> Trim / Break -> Trim / Break ■ select Trim 1 Entity Mastercam X prompts for geometry to trim. ■ select as shown in Figure 5.3.2
Figure 5.3.2: Trim selection. ■ select OK Your drawing should look like Figure 5.3.3.
Figure 5.3.3: First trim. You will now offset three lines to create the framework for the remaining geometry.
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Chapter 5: Spider Gear Carrier
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■ select Xform -> Xform Offset... ■ select Copy In the distance field: ■ type 0.05 press ENTER
Mastercam X prompts for geometry to offset: ■ select the three lines and directions as shown in Figure 5.3.4
Figure 5.3.4: Offset selection. ■ select OK ■ select Screen -> Clear Colors Your drawing should look like Figure 5.3.5.
Figure 5.3.5: Offset lines. Trim the lines: ■ select Edit -> Trim / Break -> Trim / Break ■ select Trim 1 Entity Mastercam X prompts for geometry to trim.
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■ select the 6 lines as shown in Figure 5.3.6
Figure 5.3.6: Selection for second trim. Your drawing should look like Figure 5.3.7.
Figure 5.3.7: Second trim. You should still be in Trim / Break mode. There are three more entities to trim: ■ select Divide Mastercam X prompts for geometry to divide.
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Chapter 5: Spider Gear Carrier
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■ select as shown in Figure 5.3.8
Figure 5.3.8: Divide selection. ■ select OK Your drawing should look like Figure 5.3.9.
Figure 5.3.9: Divide removes unwanted geometry. Delete the two unneeded horizontal lines:
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■ select the two lines shown in Figure 5.3.10
Figure 5.3.10: Select lines to delete. ■ press DELETE Mastercam X removes the lines. Finally, create two lines to connect the inner and outer frames: ■ select Create -> Line -> Create Line Endpoint... Mastercam X prompts for endpoints. ■ select the four endpoints as shown in Figure 5.3.11
Figure 5.3.11: Select these points to create lines. ■ select OK
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Your drawing should look like Figure 5.3.12.
Figure 5.3.12: Lines created. Save your drawing: Since you are saving for the first time, Mastercam X displays the Save dialog. In the File name field: ■ type CARRIER plus your initials. Example: CARRIERNWT ■ select Save Mastercam X saves your file.
Section 4: Fillets Now that the basic geometry is complete, create fillets to smooth the corners of the carrier: ■ select Create -> Fillet -> Fillet Entities... ■ press R ■ type 0.25 press ENTER Mastercam X prompts for geometry to fillet: ■ select the four lines as shown in Figure 5.4.1
Figure 5.4.1: Selection for first fillets.
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This book is to be distributed freely and may be copied or printed as needed. ■ select Apply Change the radius and create the second set of fillets: ■ press R ■ type 0.0625 press ENTER Mastercam X prompts for gemetry to fillet: ■ select the 8 lines as shown in Figure 5.4.2
Figure 5.4.2: Selection for second fillets. ■ select OK Your drawing should look like Figure 5.4.3.
Figure 5.4.3: Complete geometry.
Section 5: Stock Setup Before creating the toolpath, tell Mastercam X what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
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■ select Stock Setup
Mastercam X displays the Stock Setup dialog. Set your parameters as shown in Figure 5.5.1:
Figure 5.5.1: Stock Setup dialog. ■ select OK
Section 6: Contour Toolpath The carrier will be machined with a contour toolpath. Create it now: ■ select Toolpaths -> Contour Toopath... ■ select Chain Mastercam X prompts for geometry. ■ select anywhere on the carrier geometry The direction arrow should be pointing up. If it is not: ■ select Reverse Confirm the selection: ■ select OK Mastercam X displays the Contour (2D) dialog. Select a tool: ■ select Select library tool... Mastercam X displays the Tool Selection dialog.
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■ select #232 Endmill1 Flat 0.125" as shown in Figure 5.6.1
Figure 5.6.1: #232 1/8" endmill. ■ select OK Mastercam X redisplays the Contour (2D) window. Set the Toolpath Parameters as shown in Figure 5.6.2.
Figure 5.6.2: Toolpath Parameters.
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Chapter 5: Spider Gear Carrier
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Fill out the Contour Parameters tab as shown in Figure 5.6.3.
Figure 5.6.3: Contour Parameters. ■ select Depth cuts... Mastercam X displays the Depth cuts dialog. Match your settings with those in Figure 5.6.4.
Figure 5.6.4: Depth cuts settings. ■ select OK ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 5.6.5.
Figure 5.6.5: Correctly toolpathed part.
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Save your drawing:
■ select File -> Save
Section 7: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1 Mastercam X displays the Verify Controller, changes your view to isometric and fits your part to screen. ■ select Simulate Tool ■ select Machine Mastercam X machines your part. You can control the speed and quality by adjusting the options in the Verify Controller. When your part is machined, it should look like Figure 5.7.1.
Figure 5.7.1: Verified spider gear carrier. ■ select OK Mastercam X exits verify mode.
Section 8: Post Processing The toolpaths in this chapter are already broken into groups by tool, making it easier to post: In the Toolpaths tab on the left of the Mastercam X window: ■ select Select All Operations ■ select Post Selected Operations Mastercam X displays the Post Processing dialog.
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Chapter 5: Spider Gear Carrier
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Match the other settings with those shown in Figure 5.8.1.
Figure 5.8.1: Post Processing. ■ select OK Mastercam X displays a Save dialog for you to save your NC file. In the File name field: ■ type CARRIER plus your initials. Example: CARRIERNWT ■ select Save Mastercam X saves your NC file. Save your drawing: ■ select File -> Save
Congratulations! You have completed the Carrier Exercise!
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Chapter
6 Geometry
Crank and Wheel Hubs
➤ About this project:
Toolpath
Abstract Create wheel hubs and a crank for the assembly.
Description Althought these parts have no functional aspect, they do help to show off your work.
Materials 4"x5"x0.25" Acrylic.
Machines 1/4" Flat Endmill, 1/8" Flat Endmill
Verified
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Chapter 6: Crank and Wheel Hubs
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Section 1: Setup Start Mastercam X. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X does not do this automatically. ■ select Machine Type -> Mill -> Mill 3 - Axis VMC.MMD Mastercam X creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Stock Setup Before creating the geometry, tell Mastercam X what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
■ select Stock Setup
Mastercam X displays the Stock Setup dialog. Set your parameters as shown in Figure 6.2.1:
Figure 6.2.1: Stock Setup dialog. ■ select OK
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Section 3: Wheel Hub Geometry Create the geometry for a single wheel hub: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
select Create -> Arc -> Create Circle Center Point... press D type 2.0 press ENTER press SPACE type X1.25 Y1.25 press ENTER select Apply press D type 0.5 press ENTER press SPACE type X1.25 Y1.25 press ENTER select OK
Mastercam X creates the two circles. Your drawing should look like Figure 6.3.1.
Figure 6.3.1: Circles for wheel hub. Create bolt hole points: ■ select Settings -> Run User Application ■ - OR ■ press ALT-C Mastercam X displays the Open dialog. ■ select BoltCircle.dll ■ select Open
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Chapter 6: Crank and Wheel Hubs
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Mastercam X displays the Bolt Circle dialog. Match your settings with those shown in Figure 6.3.2.
Figure 6.3.2: Bolt circle parameters. ■ select OK Mastercam X prompts for a location to center the points.
■ select Arc Center ■ select anywhere on the smaller circle Mastercam X creates the points. Your drawing should look like Figure 6.3.3.
Figure 6.3.3: Points for bolt holes. Save your drawing: Since you are saving for the first time, Mastercam X displays the Save dialog. In the File name field: ■ type CRANK plus your initials. Example: CRANKNWT ■ select Save Mastercam X saves your file.
Section 4: Copy Wheel Hub Duplicate the wheel hub: ■ select Xform -> Xform Translate... Drag a selection window completely around the wheel hub.
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This book is to be distributed freely and may be copied or printed as needed. ■ select End Selection Mastercam X displays the Translate dialog. ■ select Copy ■ select Select FROM point Mastercam X prompts for a starting point:
■ select Arc Center ■ select the small circle Mastercam X prompts for an end point: ■ press SPACE ■ type X3.75 Y2.75 press ENTER ■ select OK Mastercam X copies the wheel hub. Your drawing should look like Figure 6.4.1.
Figure 6.4.1: Copied wheel hub. Save your drawing: ■ select File -> Save
Section 5: Crank Now that the wheel hub geometry is complete, create the crank geometry: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
select Create -> Arc -> Create Circle Center Point... press D type 0.625 press ENTER press SPACE type X0.61 Y3.39 press ENTER select Apply press D type 0.5 press ENTER press SPACE type X2.34 Y2.39 press ENTER
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■ select OK Mastercam X creates the two circles. Your drawing should look like Figure 6.5.1.
Figure 6.5.1: Circles for crank. Next, connect the crank circles with two lines: ■ select Create -> Line -> Create Line Endpoint... Mastercam X prompts for endpoints. Make sure the Tangent
option is selected (button will be depressed.)
■ select the four points shown in Figure 6.5.2
Figure 6.5.2: Connect the two crank circles. ■ select OK
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Your drawing should look like Figure 6.5.3.
Figure 6.5.3: Connected crank circles. Trim the crank circles to the connecting lines: ■ select Edit -> Trim / Break -> Trim / Break ■ select Trim 1 Entity Mastercam X prompts for entities to trim: ■ select the 4 entities as shown in Figure 6.5.4
Figure 6.5.4: Select first set ofentities to trim.
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■ select the second 4 entities as shown in Figure 6.5.5
Figure 6.5.5: ■ select OK Your drawing should look like Figure 6.5.6.
Figure 6.5.6: Trimmed crank. Save your drawing: ■ select File -> Save
Section 6: Drill Points Create drill points on both ends of the crank and at the center of the wheel hubs: ■ select Create -> Point -> Create Point Position... ■ select Arc Center ■ select the top crank arc
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This book is to be distributed freely and may be copied or printed as needed. ■ select Arc Center ■ select the bottom crank arc ■ ■ select Arc Center ■ select the small inner heel hub circle on the left ■ select Arc Center ■ select the small inner wheel hub circle on the right ■ select OK Your drawing should look like Figure 6.6.1.
Figure 6.6.1: Crank drill points. Save your drawing: ■ select File -> Save
Section 7: Pocket Toolpath The first toolpath you will create is a pocket toopath to machine the top of the wheel hub: ■ select Toolpaths -> Pocket Toolpath... ■ select Area Mastercam X prompts for geometry to toolpath.
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Chapter 6: Crank and Wheel Hubs
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■ select the two wheel hubs as shown in Figure 6.7.1
Figure 6.7.1: Select these two areas. ■ select OK Mastercam X displays the Pocket (Standard) window. Select a tool: ■ select Select library tool... Mastercam X displays the Tool Selection dialog. ■ select #235 Endmill1 Flat 0.2500" as shown in Figure 6.7.2
Figure 6.7.2: #235 1/4" endmill. ■ select OK
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Set your Toolpath Parameters as shown in Figure 6.7.3.
Figure 6.7.3: Toolpath Parameters. Set your Pocketing Parameters as shown in Figure 6.7.4.
Figure 6.7.4: Pocketing Parameters.
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Chapter 6: Crank and Wheel Hubs
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Set your Roughing/Finishing Parameters as shown in Figure 6.7.5.
Figure 6.7.5: Roughing/Finishing Parameters. ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 6.7.6.
Figure 6.7.6: Pocket toolpath. Save your drawing: ■ select File -> Save
Section 8: Drill Toolpath ■ select Toolpaths -> Drill Toolpath... Mastercam X displays the Drill Point Selection dialog. Move the dialog out of the way so you can see your entire drawing. ■ ■ ■ ■
select Entities select All select Points select OK
■ select End Selection
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This book is to be distributed freely and may be copied or printed as needed. ■ select OK Mastercam X displays the tool parameters screen. Do not select OK until all three tabs of parameters have been set. Use the same 1/4" Endmill as before: Set your Tool Parameters as shown in Figure 6.8.1.
Figure 6.8.1: Tool Parameters. Match your Peck Drill (Simple Drill) parameters with those shown in Figure 6.8.2.
Figure 6.8.2: Simple Drill Parameters. ■ select OK
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Chapter 6: Crank and Wheel Hubs
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Mastercam X creates the toolpath. Your drawing should look like Figure 6.8.3
Figure 6.8.3: Drill toolpath. Save your drawing: ■ select File -> Save
Section 9: Contour Toolpath Create a contour toolpath to machine around the edges of the crank and wheel hubs: ■ select Toolpaths -> Contour Toopath... ■ select Chain Mastercam X prompts for geometry. ■ select the two circles and the crank chain as shown in Figure 6.9.1 Make sure to select close to where the arrows are pointing.
Figure 6.9.1: Selection for contour toolpath. Each direction arrow should be pointing down. If it is not: ■ select Reverse
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This book is to be distributed freely and may be copied or printed as needed. ■ select OK Mastercam X displays the Contour (2D) dialog. Select a tool: ■ select Select library tool... Mastercam X displays the Tool Selection dialog. ■ select #232 Endmill1 Flat 0.125" as shown in Figure 6.9.2
Figure 6.9.2: #232 1/8" endmill. ■ select OK Mastercam X redisplays the Contour (2D) window. Set the Toolpath Parameters as shown in Figure 6.9.3
Figure 6.9.3: Toolpath Parameters.
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Chapter 6: Crank and Wheel Hubs
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Fill out the Contour Parameters tab as shown in Figure 6.9.4.
Figure 6.9.4: Contour Parameters. ■ select OK Mastercam X creates the toolpath. Your drawing should look like Figure 6.9.5.
Figure 6.9.5: Correctly toolpathed part. Save your drawing: ■ select File -> Save
Section 10: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1 Mastercam X displays the Verify Controller, changes your view to isometric and fits your part to screen.
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This book is to be distributed freely and may be copied or printed as needed. ■ select Simulate Tool ■ select Machine Mastercam X machines your part. You can control the speed and quality by adjusting the options in the Verify Controller. When your part is machined, it should look like Figure 6.10.1.
Figure 6.10.1: Verified crank and wheel hubs. ■ select OK Mastercam X exits verify mode.
Section 11: Post Processing The toolpaths in this chapter are already broken into groups by tool, making it easier to post: In the Toolpaths tab on the left of the Mastercam X window: ■ select Select All Operations ■ select Post Selected Operations Mastercam X displays the Post Processing dialog. Match the other settings with those shown in Figure 6.11.1.
Figure 6.11.1: Post Processing. ■ select OK Mastercam X displays a Save dialog for you to save your NC file. In the File name field:
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Chapter 6: Crank and Wheel Hubs
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■ type CRANK plus your initials. Example: CRANKNWT ■ select Save Mastercam X saves your NC file. Save your drawing: ■ select File -> Save
Congratulations! You have completed the Crank and Wheel Hub Exercise!
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Chapter
7 Finished Part
Differential Assembly
➤ About this project:
Abstract Assemble the gears you have created into the differential assembly.
Description All of the parts you have created so far are part of the differential assembly. In this chapter, you will combine the gears, housing, carrier, crank and wheel hubs along with simple construction to make the final assembly.
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Chapter 7: Differential Assembly
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Section 1: Materials: Spacers, Rods and Axles Before you can assemble the differential, you must gather some materials. Spacers: The spacers are 1/2" Acrylic dowel with a 1/4" hold drilled though the center. These can be made either by hand (faster) or using Mastercam Lathe. The following spacers are required for the differential: ● (1) Ring Gear Spacer, 3/4" thick ● (7) Spacers, 1/8" thick Axles: The axles are 1/4" diamter Acrylic dowel. The following axles are required: ● (1) Ring Gear Axle, 4.0" ● (1) Spider Gear Axle, 3.5" ● (1) Spider Carrage, 1.75" ● (1) Pinion Gear Shaft, 2.0" ● (1) Crank Handle Shaft, 1.0"
Section 2: Materials: Frame The frame consists of four acrylic walls, three with a hole through which the axle housings will fit. Schematic for side walls:
Figure 7.2.1: Side wall schematic.
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Schematic for top wall:
Figure 7.2.2: Top wall schematic. When assembled, the frame should look like this:
Figure 7.2.3: Assembled frame.
Section 3: Assembly Step 1: Frame
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Chapter 7: Differential Assembly
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Once you have drilled the holes in the three frame walls, glue the top and bottom pieces onto the side as shown in Figure 7.3.1. When you are done, you will have 4 of the 6 walls of a box. Make sure that the holes on the sides are closest to the top wall.
Figure 7.3.1: Frame. Step 2: Axle Housings After the frame is set, glue the axle housing into the holes as shown in Figure 7.3.2. Make sure tha tthe axle housings are glued into the side holes while the drive shaft housing is glued into the top hole.
Figure 7.3.2: Housing. Step 3: Pinion Gear Insert the 2.0" rod used for the drive shaft down thorugh the drive housing and into the pinion gear as shown in Figure 7.3.3. You will need the following parts:
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● (2) 1/8" Pinion Gear Spacers ● (1) 2.0" Drive Shaft ● (1) Pinion Gear
Figure 7.3.3: Pinion. Glue the Pinion Gear to the rod. After the glue has set, slide the rod upwards until the gear is snug against the spacer. Glue the top spacer to the rod. Make sure not to glue the spacer to the housing. Step 4: Spider Carrier The following materials are required: ● (1) Spider Gear Carrier ● (2) 1/8" Spider Gear Spacers ● (2) Spider Gears ● (1) 1.75" Spider Carrier Shaft Slide the shaft though one side of the carrier, though one spacer, two pinion gears, the other spacer, and finally the other side of the carrier. Glue the rod to the carrier. Your part should look like Figure 7.3.4
Figure 7.3.4: Carrier. Step 5: Ring Gear You will need the following materials:
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Chapter 7: Differential Assembly ● ● ● ● ●
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(1) Ring Gear (1) 3/4" Ring Gear Spacer (1) Spider Gear (1) 1/8" Spider Gear Spacer (1) 4.0" Ring Gear Shaft
Slide the shaft through the axle housing, through the 3/4" spacer, then the Ring Gear, then the 1/8" spacer, then into the Spider Gear. Glue the spider gear to the rod, but do not glue the Ring gear. It must be able to spin independently of the Ring Gear. When finished, it should look like Figure 7.3.5.
Figure 7.3.5: Ring gear assembly. Step 6: Spider Carrier You will need the following materials: ● (1) Carrier Assembly Glue the Spider Gear Carrier to the Ring Gear. You will notice that the lip on the end of the carrier will fit snugly into the ring gear at its widest diameter. Glue it at this point. The spider gear on the ring gear shaft should interact properly with the spider gears on the carrier. When complete, your part will look like Figure 7.3.6.
Figure 7.3.6: Carrier assembly attached. Step 7: Last Axle You will need the following materials:
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● (1) Spider Gear ● (2) 1/8" Spacers ● (1) 3.5" Spider Gear Axle
Slide the shaft through the axle housing, through the 1/8" spacer, through the carrier, through the second 1/8" spacer, and into the Spider Gear. Glue the shaft to the Spider Gear. When complete, your part should look like Figure 7.3.7.
Figure 7.3.7: Last axle assembled. Step 8: Crank and Wheel Hubs You will need the following materials: ● (1) Crank ● (1) 1.0" Crank Handle Shaft Glue the crank to the drive shaft on top. Glue the Crank Handle Shaft into the crank. When completed, your part will look like Figure 7.3.8.
Figure 7.3.8: Gear assembly complete.
Congratulations! You have successfully completed the differential assembly project!
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Appendix
A Appendix A
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Appendix A
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Section 1: Elements of a Gear Tooth Top Land: An arc at the top of a spur gear or the bottom of an internal gear. Bottom Land: An arc at the bottom of a spur gear or at the top of an internal gear. Involute Curve: An involute is the shape that the end of a string traces as it is unwound from a cylinder. Root Fillet: An arc that is tangent to the bottom land and the involute curve. Top Fillet: An arc that is tangent to the top land and the involute curve.
Figure A.1.1: Diagram of a gear tooth.
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Section 2: Gear Parameters The gear parameters dialog is shown in Figure A.2.1.
Figure A.2.1: Gear parameters dialog. Type of gear: Selects a spur (external) or internal gear. Changes the definition of circle tooth thickness, causes the outside diameters, root diameter, fillet radius, roll diameter and roll measurement to be recalculated. Roll measurement method: Calculated from either the outside or inside of the gear. Normally, the roll measurement method and gear type are the same, but they may be different if the gear is produced with an electrode. The roll diameter and roll measurement are automatically recalculated when this parameter is modified. Number of teeth: The number of teeth in the gear. Causes the outside diameter, root diameter, fillet radius, roll diameter and roll measurement to be recomputed. Number of paris of arcs in involute: A larger number may be selected to reduce the error between the theoretical involute curve and its approximation. Pitch diameter: The diameter at which the pressure angle and tooth thickness are measured. Causes the diametral pitch, outside diameter, root diameter, root fillet radius, roll radius and roll measurement to be recalculated. Diametral pitch: Another way of entering the pitch diameter. Equal to the number of teeth divided by the Pitch diameter. Outside diameter: The diameter of the top land. Root diameter: The diameter of the bottom land. Pressure Angle: The angle between a line that is tangent to the gear and a radial line (a line passing through X0 Y0 and the intersection of the pitch circle and the gear) measured at the pitch diameter. Causes the roll measurement to be recalculated. Roll diameter: The diameter of the pin used to measure the gear. Causes the roll measurement to be recalculated Circular tooth thickness: The thickness of a tooth measured along the pitch diameter. Note that different parts of the gear are measured for internal and external gars. Causes the roll measurement to be recalculated. Roll Measurement: When the gear is external, the distance between the outside of the measuring pins. When internal, the distance between the inside of the measuring pins. Causes the tooth thickness to be recalculated. Flank angle: The flank angle is defined so that it is zero if the flank is tangent to the involute. Normally, the flank angle is left at zero. Root fillet radius: In Specified mode, the Root fillet radius parameter entered will be used. If Full is selected, the root fillet will have the largest possible radius. It will be tangent to the involute or flank, the bottom land, and the involute or flank of the adjacent gear.
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Appendix A
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Tip fillet radius: Radius of the fillet connected the top land to the involute.
Section 3: Bevel Gears This section will explain how the angles are calculated for a bevel gear. Refer to the drawing in Figure A.3.1:
Figure A.3.1: Bevel gear diagram. The pitch of bevel gears is measured at the large end of the tooth, and both the circular pitch and the pitch diameter are calculated in the same manner as for a spur gear. The pitch angles, or in this case, the pinion gear and ring gear angles, are defined by the pitch cones meeting at the apex, as shown in Figure A.3.1. The next four equations will show how to calculate the various angles and dimensions necessary for creating bevel gear geometry. First, define variables: ● ● ● ● ● ● ● ● ● ● ● ●
rp = Pinion Gear Radius = 0.375" rr = Ring Gear Radius = 1.25" ar = Ring Gear Angle ap = Pinion Gear Angle np = Number of teeth on Pinion Gear nr = Number of teeth on Ring Gear = 40 dr = Depth of Ring Gear dp = Depth of Pinion Gear = 0.25" rbr = Radius of the Bottom Pitch of the Ring Gear = 1.25" rtr = Radius of the Top Pitch of the Ring Gear = 1.0" rbp = Radius of the Bottom Pitch of the Pinion Gear = 0.375" rtp = Radius of the Top Pitch of the Pinion Gear
Equation 1 ar = atan(rp/rr) ar = atan(0.375/1.25) ar = 16.7°
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Equation 2
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Since the two gears mesh at 90° to find the Pinion Gear Angle all you have to do is subtract the Ring Gear Angle from 90° ap = 90°- ar ap = 90° - 16.7° ap = 73.3° Equation 3 The number off teeth that each gear has to have is also related to these pitch angles. This relationship is expressed in the following equation: tan(ar) = np/nr The unknown is np, since the ring gear has 40 teeth. Thus, the equation becomes: tan(ar) = np/nr tan(16.7°) = np/40 np = 40 * tan(16.7°) np = 12 There are two possible unknowns at this point, the depth of the gear teeth and the pitch diameter of the gear at the top of the bevel gear. Choosing a value for one will allow you to solve for the other. The top pitch diameter is 2.0". Equation 4 By the laws of similar triangles, as shown in Figure A.3.2, the following equation is produced.
Figure A.3.2: rbr/rpb = rtr / (rbp - dr) dr = -((rbp / rbr) * rtr - rbp dr = -((0.375" / 1.25") * 1.0" dr = 0.075" Equation 5 To calculate the depth of the pinion gear, use the following equation: rbp / rbr = rtp / (rbr - dp) rtp = (rbp / rbr) * (rbr - dp) rtp = (0.375" / 1.25") * (1.25" - 0.25") rtp = 0.3"
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Appendix A
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Thus, the Top Pitch Diameter for the pinion gear is 0.6"
Section 4: 2D Tooth to 3D Tooth The first set of equations that you will need to use determine the angle that a two dimensional tooth will need to be rotated to make it a three dimensional tooth. Figure A.4.1 shows a side view of the ring gear. The Top circle is a circle that represents the pitch diameter of the gear teeth at the top of the bevel. The Bottom circle represents the pitch diameter of the gear teeth at the bottom of the bevel.
Figure A.4.1: Finding tooth angle. Looking at the Ring Gear from the side you will notice that the teeth move down a slope. The angle of the slope is marked as Angle A in Figure A.4.1. Recalling equations for right triangles, A = atan(rise/run). If you look at the Figure A.4.1 you will notice that the tooth makes a 90° angle with the slope of the bevel gear. This means that the desired angle is going to be 90 - A. Next, you need to find the values for Rise and Run. The Rise is going to be the depth difference between the Top Circle and the Bottom Circle. In this case, the Top Circle is 0.25" deep while the Bottom Circle is 0.325" deep. Thus, Rise = 0.375" - 0.25" = 0.074". The Run is the difference between the radius of the Bottom Circle and the radius of the Top Circle. In this case it would be Run = 1.25" - 1.0" = 0.25" Thus, Desired Angle = 90 - atan(0.75" / 0.25") = 73.3°
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Glossary
Glossary
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Glossary
2
This book is to be distributed freely and may be copied or printed as needed. Chaining Window
2D 2 Dimensional. When in this mode, Mastercam X creates all entities on the specified Cplane, such as Top, Front, or Right Side. Entities are also created at the set Z depth.
A window that appears during operations that require selected geometry. The dialog allows you to select geometry using Chain, Area, Window, Single, Polygon, Vector, or Partial selection modes. It allows allows for the unselecting of geometry, or for the reversal of the direction indicator, should it apply.
Chamfer The trimming of two intersecting lines by a third line of any length. The line is created at an angle equal to half of the angle of the two intersecting lines.
3 3D 3 Dimensional. When in this mode, Mastercam X allows you to create entities at any Z depth. The plane setting is still respected when creating new entities not based on existing geometry. When creating entities based off of other entities, however, the Cplane is ignored. This allows you to link other geometry without setting the correct Cplane.
A
Context Menu A menu that appears when right-clicking in the drawing area. By default, it contains functions for setting the Gview and controlling Zoom levels. You can also customize it by adding any function you wish
Contour Usually refers to a toolpath. The toolpath will follow specific geometry, either on the left or right sides, or centered on the geometry. A contour can also be a name for geometry.
Coordinates
Arc A section of a circle, usually created by specifying a radius or diameter and a start and end angle. The 0 angle position is along the positive X axis.
Cartesian coordinates refer to measurements in 2D or 3D using the X, Y, and Z values. The origin is X0 Y0 Z0. Polar coordinates are specified with a radius an an angle.
Cplane
B
Short for construction plane. Refers to the plane on which new geometry will be created, if the 2D/3D mode is set to 2D. This plane is independent of the Gview and Tplane.
Backplot
Cylinder
A function similar to verification that allows you to step though a toolpath's operation. The tool is drawn directly on your existing drawing. As the toolpath progresses, it's path is drawn on the screen.
A primative cylinder can be created either as a solid or a surface. It is made by extruding a circle to a specified height.
Bevel The angle or inclination of a line or surface that meets another at a non-90° angle. Two rules joined together as adjustable arms used to measure or draw angles of any size or to fix a surface at an angle. Also called bevel square.
Block Refers to one of the provided Mastercam fonts for lettering.
Boolean Add A solid modifier that combines two solids by adding their structures.
Boss A boss surface is one that will be machined by cutting up to its outer limits.
D Differential A bevel gear that permits rotation of two shafts at different speeds; used on the rear axle of automobiles to allow wheels to rotate at different speeds on curves.
Draft A surface created from a single geometry entity. Parameters allow you to specify length and angle of the surface.
Drill Toolpath used to drill holes in stock. Parameters allow for multiple drills in a single toolpath, as well as drill hole arrays.
Dynamic
A font provided by Mastercam commonly used for lettering.
A method for rotating your Gview in 3D in real time. Moving the mouse rotates the Gview, so all sides of the part can be seen.
C
E
Cavity
Endpoint
Box
A surface that will be machined by cutting out its insides.
Chain A selection mode that will select all geometry connected to the entity selected with the cursor.
The point corresponding to the end of the a line, arc, or other 2D geometry.
Extrude A method of creating a solid by adding thickness to a closed planar chain.
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Masterwork Solutions
Mastercam X Gears Tutorial
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F
Geometry made of arcs and lines that forms Roman characters. Used for
Fillet
Line
An arc created at the intersection of two 2D entities. Used primarily to smooth sharp corners cause by two intersecting lines. Similar to a chamfer, but used with
A single linear geometric entity in Mastercam X, defined by its two endpoints.
Linear
Filter Used in the tool manager to limit the results displayed to a specific tool or tools.
Geometry that is linear can be duplicated by drawing a line through the two endpoints. Linear geometry has a constant slope.
Fit Screen
Loft
A function used to set the zoom exactly as it should be to view all of the geometry in the drawing at its maximum size. This can be accessed in the context menu or by pressing ALT-F1
Flat Boundary A type of surface created from a closed planar chain.
Loft surfaces are created from a set of ribs. The surface follows curvature based on the ribs. Lofted solids are created similarly, but the end result is a solid, not a surface.
M
Flowline A toolpath that cuts along the "grain" of a surface or surfaces. The tool will follow the contours of the part when machining. Both Rough and Finish versions of this toolpath are available.
MCX The file extension of a Mastercam X drawing file.
Midpoint A point on a line where the distance from the point to each endpoint is identical.
G
Mirror Gear
To move or copy geometry by reflecting it over a line.
A toothed machine part, such as a wheel or cylinder, than meshes with another toothed part to transmit motion or to change speed or direction.
MRU
Geometry Entities created in Mastercam X. Usually refers to 2D geometry such as lines, arcs, circles, and splines. Used to create other entities such as surfaces, solids, and toolpaths.
Gview Geometry view. Controls how the part is displayed on the screen. Changing the view changes how you look at the part. Common Gviews include Top, Front, and Right Side. In most parts, you will switch between Gviews often when creating geometry.
Most Recently Used toolbar. Usually appears at the right side of the Mastercam X window. Displays icons for recently used functions. Every time you use a new function it is added to this list.
N NC Numerical Code. G&M code created by a post processor. This code is sent to your CNC Mill/Lathe and instructs it how to machine your part..
O
H Horizontal A method for constraining the creation of a line. The Y value of the line remains constant.
Offset To move or copy linear by a delta value. Similar to Translate except translation can only occur in one direction. The Cplane is respected when choosing where to place the offset geometry.
Offset Contour
I Island A area in a pocket toolpath that is excluded from machining. A pocket toolpath can have multiple islands.
Similar to offset. Allows chains of geometry, including arcs and circles to be selected. If the geometry selected is a closed chain, Offset Contour scales the part larger or smaller depending on the offset side chosen.
Origin
Isometric
The point X0 Y0 Z0.
Often referred to as 2.5D. Allows you to see your part in psuedo-3D. (Isometric lacks perspective shown in true 3D)
P
L
Parallel Rough and Finish parallel toolpaths are available for machining surfaces. The tool makes parallel passes over the stock, with
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Glossary
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one or more plunges in each path. Also a method of creating lines by duplicating the slope of an existing line.
Pocket Toolpath allowing an area of your drawing to be cut to a constant depth.
Ruled
A type of surface made from a set of ribs by concatenating planar surfaces. Similar to loft except the resulting surface is not curved.
S
Point Entity representing a single point, such as X3 Y2 Z0.
Polar
Scale
A coordinate system in which points are defined in terms of a radius R and angle θ.
An Xform that transforms geometry by adjusting its size. Geometry is scaled around a point of origin. A scale factor of 1.0 indicates no change, a smaller factor will reduce the size of the part.
Post Processor An interpreter used with Mastercam X to generated the correct NC code for your CNC Mill/Lathe. The post processor should be included with the machine. Post processors for V9 will need to be updated to work with VX.
Primative A primative is a solid or surface entity that is complex to create normally. Primitives consist of Cylinders, Cones, Blocks, Spheres and Toruses.
Shading Toggles shading on or off. When shading is on, surfaces and solids are draw as such -- they are opaque. This can be helpful when visualizing your part.
Shell A solid modifier function that "shells" a solid by opening one of it's faces. The solid is then given a thickness.
Side
R
A Gview that views the part from either the left or right side.
Sketch Radial Both Rough and Finish Radial toolpaths are available for machining surfaces. The tool starts from an origin, usually in the center of the part, and proceeds to machine the part by moving around in circles.
Radius A property of an arc or circle that controls its size. The radius is half of the diameter.
Rectangle
A method of entering points by simply clicking the mouse in the drawing area. Without the autocursor, this is usually very imprecise.
Solid An entity created from wireframe geometry. Represents a real world physical entity. The chain it is created from must be closed. Solids can be created as Extrude, Revolve, Sweep or Loft. Solids can also be filleted, chamfered, trimmed and shelled.
An entity consisting of four lines.
Spline
Revolved
A continuous curve that goes through several points.
A chain of geometry can be revolved around an axis of revolution, a line, to create either a solid or surface. For solids, the chain must be closed.
Stock Setup Dialog that allows you to define the size of your stock and display it on the screen.
Rotate
Surface
An Xform method that transforms geometry by rotating it around a single point. The geometry can be either moved or copied. The current Cplane determines how the geometry will be rotated.
Rough
An entity made from wireframe geometry that specifies a 3D contour for machining. Often surfaces indicate actual faces of the final part. Surfaces can be modified using trim, extend, and fillets. Surfaces can be created as Draft, Loft, Ruled, Revolved, Swept, or Flat Boundary surfaces.
A toolpath made for machining the bulk of the stock that needs to be removed. Rough toolpaths are usually done with a moderately large tool, large step over, and a small amount of stock left on the part.
Swept A swept surface is created by "sweeping" a single contour across multiple other contours, usually 2. A swept solid is created similarly, but produces a solid instead of a surface.
N
T
Normal
Toolpath
The surface normal controls which side of the surface is the "front". Changing the normal is sometimes necessary when creating surface to surface fillets.
A toolpath is created to machine a part. It consists of instructions for how to move the tool to machine the part as desired. Many different types of toolpaths are available to cut a wide variety of parts.
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Mastercam X Gears Tutorial
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Toolpaths Tab
A tab at the left of the Mastercam X window that displays all of the toolpaths used in the drawing. It also displays the machine and stock used. Selecting these items brings up configuration windows.
Torus A type of primative created as either a surface or solid. A torus is a doughnut shaped entity.
Trim / Break A combined function in Mastercam X that integrates trim and break functions. Trim functions include Trim 1 Entity, Trim 2 Entities, Trim 3 Entities and Trim Divide. An entity is trimmed to another by either removing excess geometry past the entities' intersection or extending the geometry to the intersection.
V Verification A way to see your part as it would be machined, without machinging it.
Vertical A method for constraining the creation of a line. The X coordinate remains constant.
W Window A selection mode that allows you to drag a selection window around geometry that you want to select.
Z Zoom A function that allows you to view in detail small sections of your geometry. You can zoom in by pressing F1 and dragging a window around the area you want to view in detail. Zoom out by pressing F2
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